10.12.2018 Articles - Die Springs--Coil vs.

Gas; Best Practices | MetalForming Magazine

Subscribe | My Online Account

About Us Magazine Multimedia Enterprise Zones Web-Only Content Industry Showcase Advertise

VISIT O U R S P O NSORS
» home » magazine » 2017 » february 2017 » die springs--coil vs. gas; best practices

Articles
Back Print Article
View the February 2017 Issue Buy Reprints

SHARE:

DIE SPRINGS--COIL VS. GAS; BEST PRACTICES

By: Brad Kuvin

There are 0 comments | Post a comment

Wednesday, February 1, 2017

While the gas-spring industry has done a bang-up job earning market share from coil-spring suppliers, experts
interviewed for this article agree that you can’t paint a broad picture when it comes to selecting the right solution for
metalforming dies. Where can stampers still use coil springs? We asked Ray Osborne, vice president of sales at
Moeller Precision Tool, Wixom, MI.

“Applications where you don’t need nitrogen,” Osborne says,

“may include simpler dies where you don’t have a lot of
stripper-pad travel; flat parts that don’t have a lot of form in
them; high-speed dies; and tools requiring short strokes such
as those used to stamp electronic parts.”

On the flip side, Jim Glynn, president gas-spring supplier

Special Springs, LLC, Canton, MI, warns against painting the
die-spring picture with a broad brush, noting that the majority
of dies now are designed with gas springs.

“Coil springs exhibit some limitations, due to the greater force

required to form or strip,” Glynn says. “This becomes
increasingly important as more metalformers begin to
fabricate higher-strength materials. You don’t always have
room in the die to use as many coil springs as might be
needed. Gas springs become the default solution for these
jobs. For shorter runs and in areas where you don’t need as
much force for stripping or forming, you might be able to get
Considering a 2-in. stroke, the die designer would need a coil
away with coil springs, provided they are preloaded, and
spring with a free length of 8 in., compared to a 5.12-in. gas
properly designed and installed.” spring. Also, it would require four coil springs, fully compressed
2 in., to equal the force of one 25-mm nitrogen-gas spring.
Coil- S p r i n g C o m mandments

“With the continuing, immense pressure to reduce die cost,” explains Osborne, “it often is bewildering to see the
prevalence of nitrogen-gas cylinders in the marketplace. I often see elaborate gas-spring installations where they are
not necessarily warranted.”

In response, Glynn notes that “gas springs generally comprise less than 4 percent of total die cost.”

When metalformers do opt to use coil springs, Osborne offers this laundry list of best practices:

• Always incorporate preload (a minimum of 5 percent of free length), achieved by correctly specifying the
spool/keeper lengths used in securing the stripper pad, lifter rail or other moving element being considered.

• Ensure flatness (to within 3 percent) and

perpendicularity of the contacting surfaces, to within 1
deg. or less.

• Follow recommended guiding practices. “Guiding on

the spring ID is preferred when possible,” Osborne
says, “even though in most applications stampers wind
up guiding on the OD. But by investing a little more
upfront to guide on the ID, you create less potential
contact area and minimize wear.”

• Reduce or eliminate the possibility of scrap material or

other foreign objects becoming trapped between the
coils, by adding spring cans or other guarding to the
setup.
Among Osborn’s recommended practices for using coil die springs:
Follow recommended procedures for guiding. “Guiding on the spring

https://www.metalformingmagazine.com/magazine/article/Default.asp?/2017/2/1/Die_Springs--Coil_vs._Gas_Best_Practices 1/4
10.12.2018 Articles - Die Springs--Coil vs. Gas; Best Practices | MetalForming Magazine
• Never cut springs to length. Always purchase and ID (center illustration) is preferred,” Osborne says, “even though in
install the correct spring for the application. “Cobbling most applications stampers wind up guiding on the OD (left). But by
springs to force-fit an application is penny-wise and investing a little more upfront to guide on the ID, you create less
contact area and minimize wear.
pound-foolish," says Osborne.

• Replace broken springs immediately, and always replace springs as a complete set.

• Be mindful of increases in deflection due to shut-height changes that result from routine die sharpening.

• Be mindful of series versus parallel arrangements. The resulting load calculations are very different.

• When inspecting springs to gauge their condition, look for worn paint or shiny surfaces, indicators that surfaces are
rubbing. “Surfaces should be free of striations or cracks,” Osborne says. “Visually inspect them every time the die
goes in for sharpening or general maintenance. And any time the stripper pad is removed and the springs can readily
be removed, give them a rattle—if they’re cracked you will hear or feel it.”

Sprin g S e l e c t i o n—Shoot for Two out of Three

When selecting the right coil spring for the job at hand, Osborne offers a simple and often-cited anecdote, along the
lines of ‘good quality, low price and fast delivery.’

“Typically a metalformer can get any two of these three,” he says. “And with coil springs it’s the same—where the
three variables are force, deflection and spring life, and you can only get two of the three. For example, if you need a
lot of force over a large deflection, don't expect long life. In this case, nitrogen-gas springs might make sense.”

An exception to this rule, says Osborne: springs used for misfeed protection within,
say, an in-die tapping device. “You need high force and long travel,” he says, “and you
don’t care about life because the springs operate statically—in a healthy application
they never cycle. So, even though they are under considerable preload and expected
to travel a long distance, they rarely if ever actuate, so their life will not be a
consideration.”

Lastly, Osborne issues a warning to manufacturers looking to use die springs for non-
die or mold applications, which he says is becoming more common. Here the user
needs to fully understand spring rate, or the spring constant, that governs the force-
deflection curve.

“Typically, spring manufacturers provide a spring-rate tolerance of ±10 percent,”

Osborne says. “This works fine for dies and molds, but in non-tooling applications it
may not suffice; the application might require a tighter tolerance on spring rate. For
these applications, many manufacturers offer (for a premium) springs with the constant
controlled to within ±3 to 5 percent.”

Gas S p r i n g s : H e ed the End Forc e

When it comes to specifying gas springs, Glynn notes that most are rated for a
maximum speed of 1.8 m/sec., and, depending on press stroke, gas springs can run at
press rates to 200 strokes/min.—depending, of course, on the amount of stroke.

“With just a shorter stroke, less than 12 mm,” he says, “you can run with gas springs at
faster press speeds. But, with more than an inch of stroke, press speed can be limited
In gas-spring applications
to around 100 strokes/min.—the limiting factor being the heat caused from the friction
requiring a lot of die lube, be sure
and pressure rise in the springs. When selecting the right gas spring for the application,
to protect the springs from
the stamper must carefully consider the force profile needed for the entire spectrum of
contamination by using protective
forming, piercing and stripping requirements. rod covers (shown here) or
wipers. “Contamination is a
“Also important is understanding where you need the force,” Glynn continues. “Gas leading cause of spring failure,”
springs provide force on contact, and the force can increase as much as 50 percent as says Special Springs’ Jim Glynn.
the piston rod compresses. If the stripping or forming force is calculated for the end of
the stroke, then the die designer may be able to use fewer springs and reduce die cost, since the end-of-stroke force
can be significantly greater than the initial contact force.”

While most gas-spring manufacturers offer a variety of sizes in terms of force, diameter and overall length, the
industry, Glynn says, is settling in on ISO and VDI (The Association of German Engineer) standard gas springs. Most
major gas-spring manufacturers comply with these standards, which allows the springs to be interchangeable and
helping stampers reduce downtime and cost.

Glynn warns, however, that “when repairing gas springs, use the repair kit specified by the manufacturer—these are
not interchangeable. And, as a general rule, I recommend that shops only repair gas springs with a body diameter
larger than 50 mm.”

Shari n g O t h e r B est Practices

Glynn stresses that die designers should specify gas springs so that only a maximum of 90 percent of rated spring
stroke is used. “The less stroke the better,” he says, “to reduce friction and pressure and prolong spring life.”

Also sound practice: Ensure that the spring sits on a flat surface, with the rod perpendicular to the striking surface or
pad. This is critical to avoid side loading.

“To optimize spring life,” Glynn adds, “attach springs using a mount or the tapped holes in the bottom of the springs,
so they’re not loose in the die. If the springs aren’t fastened, metal contaminants or debris can wedge their way
underneath the springs, which would then create a misaligned or angled spring and lead to side loading.”

If stampers do elect to just drop the springs into the pockets machined into the die, Glynn suggests that they design
the pockets with clearance based on the manufacturer’s recommendations, to minimize the chance of contamination.

https://www.metalformingmagazine.com/magazine/article/Default.asp?/2017/2/1/Die_Springs--Coil_vs._Gas_Best_Practices 2/4
10.12.2018 Articles - Die Springs--Coil vs. Gas; Best Practices | MetalForming Magazine
And, in applications requiring a lot of die lube, use springs with protective rod covers or wipers to guard against
contamination, “a leading cause of spring failure,” he says.

Conne c t i n g G a s Springs to Cont rol, Adjust Force

Hosed or linked nitrogen systems provide the most flexibility for metalforming. “Gas springs can be linked together,”
Glynn explains, “with a series of high-pressure hoses, or via a 1-in. manifold plate. This system is the cleanest and, I
believe, the most reliable.”

To take this a step further, designers can add pressure switches (electronic pressure monitors) to the system, Glynn
says, allowing the stamper to set parameters based on the pressure profile that optimizes part quality. And, should
pressure fall below a certain level, due to a leak in the system, it signals the press to stop.

A great example of the benefits of connecting gas springs via a manifold setup, says Osborne: in-die tapping, where
considerable stripper travel is needed to locate and control the part during the tapping operation.

“In some cases,” Osborne notes, “the tapping unit is mounted in the upper die, within the stripper. It is critical that
those gas springs be linked together to ensure uniform balance in the stripper pad. Otherwise, should one or two gas
springs go flat in one corner, the stripper won’t hold down firmly in that corner, which can wreak havoc with the
tapping unit and lead to broken taps and cause damage to the unit. It’s mandatory that stampers use a manifold when
using nitrogen for in-die tapping operations.”

A Cri t i c a l N o t e A bout Safety

Lastly, Glynn notes a relatively new focus on safe use of gas springs, which came to light in November 2015 when
VDI added new safety guidelines to its VDI 3003 Standard, “Nitrogen Gas Springs in Large Stamping and Forming
Dies.” These guidelines arose from the fact that gas springs, under high pressure require that safety be top of mind.

“Because these springs contain a lot of pressure,” Glynn says, “which can range from 2000 to more than 4000 psi
during compression, they’re nothing to fool around with. Because of this, we and other manufacturers have focused
on developing new safety features, following the VDI guidelines. These fall into three categories: protection from
over-stroke and over-pressure, and protection from return stroke without counterforce.”

Here’s the language contained in the VDI standard:

• Return stroke of nitrogen-gas spring without counterforce

Do not use gas springs in such a way that the piston rod is released freely from its compressed position. This can be
caused by a jammed pressure pad or cam. As a result, the nitrogen gas spring exceeds the permitted speed during
the return stroke, causing the piston rod to slam unchecked onto bushing. This can damage the nitrogen-gas spring
or cause it to fail (high-speed return of the rod). To avoid this, use only nitrogen-gas springs that are designed to vent
gas, thereby depressurizing the spring.

• Over-stroke

Over-stroke occurs when the piston rod is pushed deeper into the gas-spring body than the nominal stroke length.
This can damage the gas spring. Use only gas springs that are designed to vent the gas completely to atmosphere in
a controlled manner in the event of over-stroke.

• Over-pressure

Gas springs can break if the pressure inside rises due to fluid penetration or incorrect charging above the permitted
limit. If fluids are used, it is advisable to ensure that gas springs have over-pressure protection. When the over-
pressure-protection system is triggered, the gas is vented safely. MF

See also: Moeller Precision Tool

Related Enterprise Zones: Tool & Die

READER COMMENTS
There are no comments posted at this time.

POST A COMMENT
* Indicates field is required.

YOUR COMMENTS * (You may use html to format)

YOUR NAME * EMAIL * WEBSITE

Nie jestem robotem

reCAPTCHA
Prywatność - Warunki

> Submit

https://www.metalformingmagazine.com/magazine/article/Default.asp?/2017/2/1/Die_Springs--Coil_vs._Gas_Best_Practices 3/4
10.12.2018 Articles - Die Springs--Coil vs. Gas; Best Practices | MetalForming Magazine

PMA Services, Inc. Home :: Contact :: Sitemap :: Advertise The official publication of
6363 Oak Tree Blvd.,
Independence, Ohio 44131-2500
P: 216-901-8800
F: 216-901-9669 Precision Metalforming Association
> Send feedback
© 2018 Precision Metalforming Association. Terms and Conditions

https://www.metalformingmagazine.com/magazine/article/Default.asp?/2017/2/1/Die_Springs--Coil_vs._Gas_Best_Practices 4/4