Essentially straight wire is fed into a coiler through a number of coiling rollers that lead to a set of coiling points that apply pressure to create the precision spring product. Seemingly simple when looking at our video but years of engineering expertise and advanced technologies ensure the process of bespoke manufacturing a metal spring is precise, efficient, fit for purpose and secures a quality, accurate product with the longevity of use.
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The coil spring manufacturing process starts with a client consultation, then design, and progresses to material selection before passing through a number of development, manufacturing and production processes. As specialist heavy spring manufacturing experts our spring manufacturing process includes hot and cold coiling spring manufacturing equipment, including the largest Wafios CNC coiler in the world. The coiling is just part of the journey, as the full spring manufacturing process also requires heat treatment, shot peening, grinding, powder coating and finishing
Coil springs can be manufactured through either cold wound or hot wound coiling processes.
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In hot wound coiling, the material is heated to austenitic temperatures of over 1550F, formed on the coiler, and then quenched in oil to form martensite. Next, the springs are tempered to change the microstructure to a tempered martensite which provides strength to achieve the desired spring performance and ductility to withstand the operation. Hot wound coiling is usually for larger bars sizes over 0.500” (12 mm). MW's Greer location can coil bars up to 3.00” (75 mm) in 5160H, 51B60H and 4161H material. Additional materials, such as Inconel and Stainless Steel, can be coiled through hot winding, but these materials are not included in our standard raw material inventory.
MW Components utilizes a continuous heat-treating process to manufacture hot coiled springs. Every bar and every spring in a lot goes through the entire length of the furnaces. This means that each bar, and therefore each spring, gets a consistent heat treatment and is not dependent on its position in the furnace. This is a distinct advantage over batch processes where each spring receives a different heat treatment depending on where and when the material is placed in the furnace.
Cold coiled springs are made from fully heat-treated material and then stress relieved to remove the stresses induced during the coiling process. MW Components - Greer: Springs can coil up to 0.625” (15.8 mm) in Chrome Silicon and Oil Tempered Wire. MW can also coil high tensile Chrome Silicon to 0.437” (11 mm) and in 2019 we will extend our range for high tensile Chrome Silicon over 0.625” (15.8 mm).
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