Details to Consider When Choosing Leaf Spring Suspension

As leaf springs age, they'll begin to break, crack and sag. While leaf springs get older, their steel can end up stretching. They can loosen and eventually harm your suspension system. Leaving worn-down leaf springs in your vehicle can lead to major damages. As a result, it's crucial to replace leaf springs when they start showing signs of wear.

If you need replacement leaf springs, you can choose the best leaf spring for your vehicle by knowing more about the differences between stock leaf springs and heavy-duty leaf springs. You may also want to learn more about the details that make some leaf springs superior to others.

Choosing Between Stock Leaf Springs or Heavy-Duty Leaf Springs

When you're shopping for leaf springs, you'll likely want to consider the difference between heavy-duty leaf springs and stock leaf springs. One option may be superior for your specific application, so it's crucial to know the difference between them and what duties they can handle. Below, learn more about how to choose a leaf spring for your needs.

When You Need Stock Leaf Springs

Leaf springs will stretch over time, leading your vehicle to sag. This phenomenon can eventually lead to a breakdown or put the vehicle in harm's way. Stock leaf springs are usually best for those who are happy with their vehicle's performance and need to replace leaf springs that have worn down over repeated use.

When you're looking to get your vehicle back to its optimal riding height and original condition, stock leaf springs are going to be ideal. General Spring offers many standard original equipment manufacturer (OEM) leaf spring options for trucks and cars to get your vehicle in working order. By putting these OEM leaf springs in, you'll return your vehicle to stock condition and have many years of safe and comfortable driving ahead of you.

When You Need Heavy-Duty Leaf Springs

If you're not looking to restore your truck's original condition and instead want to increase its load capacity, you may want to choose heavy-duty leaf springs instead. When you upgrade to heavy-duty springs, your truck, SUV, car or van will be able to carry more weight. This increase in load capacity can reduce the amount of time it takes to complete a hauling job, as you don't have to take as many trips.

At General Spring, we're here to provide our customers with heavy-duty leaf springs that will increase their vehicles' efficiency. We even carry SuperSprings, which are additional attachments to the standard design leaf spring that provide added capabilities and load tolerance.

Why Choose Leaf Springs From General Spring?

At General Spring, we know that details matter. Over the years, we've learned a few tips for improving leaf springs for better performance above and beyond what OEMs require. One major modification we've implemented is an improved clip design incorporating metal riveted clips with clip bolts.

By using this design, you get extra strength on the clips, thus eliminating the squeaking that sometimes occurs in this section of the leaf spring. Our improvements over OEM specifications and unbeatable prices set General Spring leaf springs apart from the competition in the industry.

Choose General Spring for Leaf Springs

The team at General Spring specializes in leaf springs for all makes and models of vehicles, so we know what it takes for a leaf spring to make your suspension system work properly. With 50 years in the business of automotive and truck suspensions, our experts have the knowledge and advice you need to pick the right product for your vehicles. We can make custom leaf springs for vehicles with hard-to-find parts.

Browse our selection of leaf springs to find the best one for your vehicle's requirements. If you have any questions, contact us today. With the best suspension products in the business and top-quality advice, you will be happy with your new suspension system.

Time to read: 5 min

Springs are common in all kinds of machines &#; from consumer products to heavy industrial equipment. Take apart anything that involves a mechanism, and chances are, you&#;ll find a spring inside. Springs are storage devices for mechanical energy, analogous to the electrical storage capacity of batteries. The earliest spring-driven clocks appeared in the s. Fast-forward some 600 years, you still have to charge your Apple Watch every day, and it&#;s not nearly as fast as winding a clock&#; so yay progress, I guess?

My personal fascination with springs began with Slinkies and wind-up toys, and countless mechanical pencils were sacrificed and deconstructed to satisfy my curiosity. These days, I appreciate the more sophisticated applications of springs &#; especially when I drive over potholes, thanks to my car&#;s modern coil spring suspension that still delivers a smooth ride!

Spring Types and Their Applications

The most common way to classify springs is by how the load is applied to them. These are the most common classifications of springs:

• Compression springs: designed to operate with a compressive load. Found in shock absorbers, spring mattresses, mechanical pencils, and retractable pens.
• Extension springs: designed to operate with a tensile load. An archetypical example is a Slinky, but extension springs are also found in luggage scales and garage door mechanisms.
• Torsion springs: designed to operate with torque (twisting force). These springs power every clothespin and mouse trap.

Within each of these different spring types are further characterizations and classifications. Next, let&#;s look at the relationship between the force applied to a spring and its resulting displacement. Again, there are three classes of springs: linear (or constant rate) springs, variable rate springs, and constant force springs.

Pro-Tip: When choosing springs for an assembly, make sure to follow Design for Assembly Rules. Use our free 10 DFA Rules to Live By Checklist. 

Linear Springs

Linear springs obey Hooke&#;s Law (F=-k*x), which means that the force needed to extend or compress such a spring by distance x is proportional to the distance, as long as the force doesn&#;t exceed the elastic limit of the spring.

Hook&#;s Law for Linear Springs: 

F=- k * x

Where: x = distance or (L2 &#; L1)

F= force needed to extend or compress the spring &#;x&#; distance

k=spring constant or spring rate

The negative sign is present in Hook&#;s Law because the restoring force is in the opposite direction of the applied force; pulling a spring down will cause a downward extension but a resultant upward force. 

Torsion springs obey an analogous version of Hooke&#;s Law (F=k*θ, where θ is an angle). In both cases, k is the spring rate, and it stays constant, no matter the spring&#;s deflection. This is why linear springs are also known as constant-rate springs.

Hook&#;s Law for Torsion Springs: 

F=- k * Θ

Where Θ=angle of deflection or twist

Variable Rate Springs

On the other hand, a variable rate spring doesn&#;t have the same spring rate throughout its axial length, in other terms &#; k is not constant. You can have a progressive change in the spring rate, or a more abrupt change &#; see the diagram below.

A familiar variable rate spring is the cone-shaped compression spring, most commonly found in battery boxes. The fully compressed height can be as low as one wire diameter. Variable rate springs also have the additional benefit of being laterally stable and less prone to buckling. Here are some additional resources for conical spring calculations for stiffness and allowable working stress.

Constant Force Springs

Constant force springs are uniquely formed with pre-tensioned metal strips, not wire as standard springs are formed from. Self-explanatory by its name, a constant force spring requires nearly the same force, no matter how long the extension. Constant force springs are also called clock springs. This type of spring is usually a coiled ribbon of spring steel used in counterbalancing applications, such as height adjustment for monitors, and &#; you guessed it &#; clocks.

Also, the term constant force spring is a little misleading. The reality is that the spring&#;s full load must be overcome by extending the spring to 125% of its original diameter &#; then a nearly constant force can be utilized to continue expanding the spring.

Manufacturing Springs

Springs can also be classified by how they&#;re made, because there are many methods for making springs. The most commonly-known is probably a metal coil spring, also known as a helical spring, but there are many other types of springs. Even an elastic band can be considered a variable rate spring, since it stores mechanical energy.

Coil Springs

Lightweight coil springs are made by forming metal wires on a CNC coiling machine. The multi-axis CNC control allows you to create variable pitches and end conditions only limited by your imagination. Springs that come off coiling machines do not have springy properties. They need to be heated to a high temperature (typically 500 degrees Fahrenheit or more) to relieve stress, then quenched to create the shape memory.

In contrast, when making heavy duty coil springs, the wire is heated up before coiling, which you can see in this video.

Flat Springs

Flat springs come in all sizes and shapes. Spring washers, PCB spring contacts, and retainer clips are all examples of flat springs. These springs are essentially sheet metal parts made by stamping. However, there are coiled flat springs as well, such as clock springs and volute springs &#; and all flat springs need be heat treated for shape memory.

Disk Springs

Belleville washers and conical springs are both common terms used in exchange for disk springs, which are disk-shped with a concave surface. They are typically made by stamping, plasma cutting, or blanking a flat sheet of metal, then the concave shape is typically machined. Disk springs can look like deformed metal washers, but they serve much more complex purposes.

Machined Springs

Machined springs and die springs are used for heavy duty applications with high strength and precision requirements. As the name suggests, machined springs are made on CNC lathes and mills.

Molded Springs

Plastic or composite springs are commonly found in corrosive environments, such as food production, medical, and marine applications. Due to creep susceptibility, they should only be used in intermittent cycles. Compared to metal springs, plastic springs are relative newcomers to the space, and supply is not as abundant.

Sourcing Springs

Now that you know more about the types of springs, it&#;s time to try some out! Coil springs and certain types of flat springs are widely available in a range of stock sizes and materials that will likely suit your application. When sourcing, be sure to specify your spring material. Here are some of the most common spring materials: 

• Beryllium copper alloy
• Ceramic
• One-directional glass fiber composite materials
• Rubber
• Urethane
• Steel alloys

Here are some suppliers of off-the-shelf springs:

And here are some other spring-related resources to learn more: 

Complex Parts at Ridiculous Speeds &#; Start Your Next Project With Fictiv

If you need parts other than springs for your next project, Fictiv can help! Whether its CNC machining, injection molding, 3D printing or urethane casting, Fictiv is your operating system for custom mechanical parts. Create an account and upload your part to see what our instant quote process, DFM feedback, and intelligent platform can do for you &#; we deliver complex parts at ridiculous speeds!

F= force needed to extend or compress the spring &#;x&#; distance

k=spring constant or spring rate

The negative sign is present in Hook&#;s Law because the restoring force is in the opposite direction of the applied force; pulling a spring down will cause a downward extension but a resultant upward force. 

Torsion springs obey an analogous version of Hooke&#;s Law (F=k*θ, where θ is an angle). In both cases, k is the spring rate, and it stays constant, no matter the spring&#;s deflection. This is why linear springs are also known as constant-rate springs.

Hook&#;s Law for Torsion Springs: 

F=- k * Θ

Where Θ=angle of deflection or twist

Variable Rate Springs

On the other hand, a variable rate spring doesn&#;t have the same spring rate throughout its axial length, in other terms &#; k is not constant. You can have a progressive change in the spring rate, or a more abrupt change &#; see the diagram below.

A familiar variable rate spring is the cone-shaped compression spring, most commonly found in battery boxes. The fully compressed height can be as low as one wire diameter. Variable rate springs also have the additional benefit of being laterally stable and less prone to buckling. Here are some additional resources for conical spring calculations for stiffness and allowable working stress.

Constant Force Springs

Constant force springs are uniquely formed with pre-tensioned metal strips, not wire as standard springs are formed from. Self-explanatory by its name, a constant force spring requires nearly the same force, no matter how long the extension. Constant force springs are also called clock springs. This type of spring is usually a coiled ribbon of spring steel used in counterbalancing applications, such as height adjustment for monitors, and &#; you guessed it &#; clocks.

Also, the term constant force spring is a little misleading. The reality is that the spring&#;s full load must be overcome by extending the spring to 125% of its original diameter &#; then a nearly constant force can be utilized to continue expanding the spring.

Manufacturing Springs

Springs can also be classified by how they&#;re made, because there are many methods for making springs. The most commonly-known is probably a metal coil spring, also known as a helical spring, but there are many other types of springs. Even an elastic band can be considered a variable rate spring, since it stores mechanical energy.

Coil Springs

Lightweight coil springs are made by forming metal wires on a CNC coiling machine. The multi-axis CNC control allows you to create variable pitches and end conditions only limited by your imagination. Springs that come off coiling machines do not have springy properties. They need to be heated to a high temperature (typically 500 degrees Fahrenheit or more) to relieve stress, then quenched to create the shape memory.

In contrast, when making heavy duty coil springs, the wire is heated up before coiling, which you can see in this video.

Flat Springs

Flat springs come in all sizes and shapes. Spring washers, PCB spring contacts, and retainer clips are all examples of flat springs. These springs are essentially sheet metal parts made by stamping. However, there are coiled flat springs as well, such as clock springs and volute springs &#; and all flat springs need be heat treated for shape memory.

Disk Springs

Belleville washers and conical springs are both common terms used in exchange for disk springs, which are disk-shped with a concave surface. They are typically made by stamping, plasma cutting, or blanking a flat sheet of metal, then the concave shape is typically machined. Disk springs can look like deformed metal washers, but they serve much more complex purposes.

Machined Springs

Machined springs and die springs are used for heavy duty applications with high strength and precision requirements. As the name suggests, machined springs are made on CNC lathes and mills.

Molded Springs

Plastic or composite springs are commonly found in corrosive environments, such as food production, medical, and marine applications. Due to creep susceptibility, they should only be used in intermittent cycles. Compared to metal springs, plastic springs are relative newcomers to the space, and supply is not as abundant.

Sourcing Springs

Now that you know more about the types of springs, it&#;s time to try some out! Coil springs and certain types of flat springs are widely available in a range of stock sizes and materials that will likely suit your application. When sourcing, be sure to specify your spring material. Here are some of the most common spring materials: 

• Beryllium copper alloy
• Ceramic
• One-directional glass fiber composite materials
• Rubber
• Urethane
• Steel alloys

Here are some suppliers of off-the-shelf springs:

And here are some other spring-related resources to learn more: 

Complex Parts at Ridiculous Speeds &#; Start Your Next Project With Fictiv

If you need parts other than springs for your next project, Fictiv can help! Whether its CNC machining, injection molding, 3D printing or urethane casting, Fictiv is your operating system for custom mechanical parts. Create an account and upload your part to see what our instant quote process, DFM feedback, and intelligent platform can do for you &#; we deliver complex parts at ridiculous speeds!

If you want to learn more, please visit our website wave spring manufacturer.