Available online at www.sciencedirect.

com

ScienceDirect
Materials Today: Proceedings 5 (2018) 8486–8494 www.materialstoday.com/proceedings

IMME17

Performance Comparison of Belleville Washer under Compressive

Load using Experimental and Simulation Methods
A.Shree Vishnu Raja, S.Veeraghavanb, Simhachalam Badec*, Krishna Srinivasd
a
Post Graduate Engineering Trainee, Corporate Technology Center, Tube Investments of India, TPI, Chennai, India.
b
Assistant General Manager, Corporate Technology Center, Tube Investments of India, TPI, Chennai, India.
c
Senior General Manager, Corporate Technology Center, Tube Investments of India, TPI, Chennai, India..
d
Senior Vice President, Corporate Technology Center, Tube Investments of India, TPI, Chennai, India.

Abstract

Belleville washers are used in the different engineering applications with standard design parameters. The present work shows
the behavior of stress and deflection of the standard Belleville washer compared to the non-standard design parameter as per the
industrial needs. Belleville washer (or) disk spring with higher height to thickness ratio i.e. (h/t) is made with a bearing flat at
upper Inner Diameter (I.D) and lower Outer Diameter (I.D) with appropriate radius over edge. The Belleville washer design
parameter is analyzed by numerical, experimental and LS-Dyna FEM simulation. FEM simulations were performed by using
commercial simulation software LS-Dyna to study the behaviors of stress and deflection of the standard and non-standard
Belleville washer. During the study it was observed that variation between simulation and experimental results. The difference
was reduced by using element formation criterion available in LS-Dyna. Finally the simulation and experiment results were
matched by using particular element formation of 8 node hexagonal elements.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and
Manufacturing Engineering (IMME17).

Keywords: Belleville washer; Compressive Load; FEM;stress & Deflection;LS-Dyna element formation.

* Corresponding author. Tel.: +0-000-000-0000 ; fax: +0-000-000-0000 .

E-mail address: simhachalamb@tii.murugappa.com

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Emerging Trends in Materials and Manufacturing Engineering
(IMME17).
 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494 8487

Nomenclature

O.D. = Maximum outside dia. (upper surface)

I.D. = Minimum inside dia. (bottom surface)
h = conical washer height (cone height)
O.H. = Over all height = Y+h
t = Actual thickness of washer
R = Radius from centre line to load bearing circle (bottom surface)
M = Ratio factor
E = Young’s modulus
f = Deflection of washer
P = Load
X = sin β. t
Y = cos β. t
Greek symbol

∂ = Ratio of diameters (O.D. /I.D.)

μ = Poisson’s ratio (0.3 for steel)
β = Cone angle of disk

1. Introduction

Belleville Springs are used in a variety of applications where high spring loads are required. They are particularly
useful where vibration, differential thermal expansion, relaxation, and bolt creep are problematic. In these days this
Belleville washer is used for some of the most important devices in our world. They can be found in satellites,
medical equipment, in houses, on machines. This is a very important washer because it can also act as a spring at the
same time. The Belleville spring is named after its founder, Julian F. Belleville, around the mid-19th century. They
were designed to take heavy loads. F. Belleville designed the washer to be a spring as well. Ever since the creation
of the Belleville washer, they’ve been used in World War 2 on German vehicles. They were used in land mines.
They even played a role on the United States vehicles also. Belleville washers will be around for a very long time.
They’ve even improved over the years, and they make the world a better place, with their abilities to take on heavy
loads. In recent years, a lot of study investigates washer performance to classify different standards. The standards
like DIN 6796, DIN 2093. These standards illustrate the maximum load values that the washer can withstand at
various deflection percentages. This washer keep bolted joints tight, efficient use of space, high spring loads with
small deflections, self-damping, long service life, load-deflection curves which can be designed for various
applications ranging from linear rates to negative rates. Stacking in "parallel" to increase load and stacking in
"series" to increase deflection. Simple adjustment to the load and deflection can be done by adding or removing
individual springs. [1] [2] [3]
A Belleville spring experiences a deflection and stress when a load is applied in the axial direction. The stress
distribution is no uniform for this spring. The axial force is applied at the periphery of the inner diameter due to
which the stresses are induced at the inner surface & at the outer surface, which depends on geometric parameters.
The deflections and the stresses induced at the inner surface and outer surface depend on the ratios of its height to
thickness (h/t) and its outer diameter to inner diameter (D/d). This work deals with the deflection and the stresses
induced in Belleville spring due to constant axial force acting on the inner surface of the conical spring for various
ratios of (h/t) & (D/d). [4]
Load Vs deflection performance for the non-standard design of Belleville washer was presented in this study.
This kind of washer can improve the manufacturing compatibility.
8488 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494

1.1. Washer geometry

The washer geometry is shown in the fig.1.in this work the sharp corners are changed with flat corners. Precise
load and stress calculation requires the determination of the washer angle β. The exact dimension of conical height
(h) determines accurate load and stress calculation.

Figure. 1 Washer Geometry

The new design is shown in the fig.2. It contains flat in upper I.D. and lower O.D. this flat assures more uniform
loading and better alignment. The washer made by unusual dimension R= O.D. /2.

Figure. 2 Washer dimension

2. Analytical Model

The Load-deflection formula was developed by J.Almen and A.Laszlo, and published in the transaction of Amer.
Society of Mechanical Engineering, May 1936, and is rendered as follow [5]

Figure. 3 standard washer nomenclatures

4 E t4 f  h f   h f  
p          1
 
1 - µ  M  O.D t  t t   t 2t  
2 2
(1)

M
6

  1 2

  Ln    2
(2)
 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494 8489

2.1. Washer at Flat

In the flattened condition, the deflection f is equal to the conical height h and the equation becomes:

4 E  h t3
Pf 
 
1   2  M  O.D 2
(3)

3. Finite Element model

Compression test of Belleville washer was simulated by using Ls-Dyna 4.0 with 3D and 2D elements. It shown in
fig.4, fig.5 and table. 1. The washer outer diameter is 160mm; inner diameter is 82mm; flat region is 2mm and over
all height is 20mm. In this simulation we applied load in one case and displacement in another case.

Figure. 4 FE meshing of washer, plates with 3D brick Figure. 5 FE meshing of washer, plates with 2D elements

The washer was modeled using 21500 bricks element with 8 nodes. The top and bottom plates were modeled
using 2092 brick element. Two plates are considered as rigid component so modeled using coarse mesh.
The fig.5 is modeled for 2D axisymmetric simulation. Bottom plate is fixed in all degrees of freedom; top plate is
free to move in one translational degree of freedom. The contact used between plates and washer was Automatic
Surface to Surface contact with the frictional co-efficient of 0.05. Washer was modeled with Linear piecewise
plastic material in Ls-dyna by using stress strain curve. The material used for washer is EN 24. The yield strength
=1200MPa; Ultimate strength =1400MPa.

Table. 1 Element formation details in Ls-Dyna software [6]

Simulation # ELFORM (Ls-Dyna element formation)

1 -1 (fully integrated S/R solid intended for elements with poor aspect ratio, efficient formulation)-3D
element
2 -2 (fully integrated S/R solid intended for elements with poor aspect ratio, accurate formulation) -3D
element
3 2 (fully integrated S/R solid )
4 3 (fully integrated quadratic 8 node element with nodal rotation) -3D element
5 18 (8 point enhanced strain solid element for linear statics only) -3D element
6 15 Axisymmetric solid (y-axis of symmetry) - volume weighted-2D element

The stress value at the center of the washer must not exceed 1400 – 1600 N/mm2 for the DIN 2093 specified
Materials) to ensure that no “permanent set” has occurred in the washer
8490 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494

4. Experimental Test

Washers were tested in a Tube products of India, Laboratory UTM machine. The washer with O.D of 160mm;
I.D of 82 mm; over all height O.H. of 20mm; flat region 2mm; thickness of 12mm were undergone experiment. The
top ram is applied with static load of 50ton on the washer to find out the deflection. Test was conducted in normal
room temperature with five different samples of same dimension. The maximum deflection can be attain by the
washer is 8.9 mm with the conical angle of 15.290. Washer was compressed 5mm which is 55% deflection

The washer is fully coated with lubricant to avoid the friction between the washer and the hardened plate. The
hardened top and bottom plates were used to avoid the deformation on plates during testing. The fig. 6 shows the
schematic representation of the full compression test setup

In fig. 6
1- Washer
2- Bottom plate
3- Top plate
4- UTM ram
Figure. 6 schematic drawing of experiment set up

Figure. 7 UTM Experiment

4.1. Experimental Design

The compression force was measured from the UTM load cell. The following testing condition to be
considered

Lubricant : Hydraulic oil

Compression speed : 10mm/min
 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494 8491

5. FEM Analysis

In simulation model the washer is pressed with two plates (top and bottom plates) respectively. The Automatic
surface to surface contact card is used for the washer and two plates. Washer was modeled with piecewise linear
plasticity material. The stress strain behavior of the model is given with the curve. When the washer is loaded,
compressive stresses result at Points I and IV. Compressive stresses typically act on the upper surface of the disc. [7]

Figure. 8 schematic representation of washer

At Point (O) between Points I and IV, the stress should not exceed the yield strength of 1400 – 1600 N/mm2 for
the DIN 2093 specified materials. Tensile stresses at second and third points are the basis for fatigue life
calculations. Tensile stresses typically act on the lower surface of the disc.

Figure.
Fig. 9 Stress
9 Stress Distribution
Distribution in washer
in washer

6. Analytical Results

Figure10 shows the force variation with the deflection pattern in the washer. For analytical study there are two
thickness washer been selected. The all other parameters are considered as same.
Fig.11 shows the comparison between analytical result and experiment results for 12mm thickness. The
following images demonstrate increase in the force while increase in displacement.
Force (KN)
Force (KN)

t=… A…

Displacement (mm) Displacement (mm)

Figure . 10 Force Vs Displacement for different thickness Figure. 11 Analytical and Experimental comparison for
12mm thickness
8492 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494

7. Experimental results

Three samples been tested in the Tube product of India, UTM machine with lubrication. The following figures
show the results of washer deflection behavior. Fig.12shows the sample 1 displacement Vs force response;
Fig.13shows the sample 2 displacement Vs force performance; Fig.14 shows the sample 3 displacement Vs force
reaction. All samples are tested in ambient temperature condition with hydraulic oil lubricant between the washer
and the plates to avoid the high stiffness behavior between metal to metal contacts. The lubricant oil causes in
reduction of friction coefficient.

Force (KN)
Force (KN)

Displacement (mm) Displacement (mm)

Figure . 12 Force Vs Displacement Figure . 13 Force Vs Displacement for
for 3mm deflection 4mm deflection
Force (KN)

Displacement (mm)

Figure . 14 Force Vs Displacement for

5mm Deflection

The comparison result of the three samples is shown in the following Fig.15. From these following results the
5mm deflection curve is taken as the reference for Ls-Dyna simulation result comparison. The experiment results
showing that up to 4mm deflection the washer didn’t attain a permanent set. Washer attained its plastic deformation
above 4mm deflection. It shows that the washer can be fully elastic in condition up to 4mm deflection.

Figure. 15 Comparison of all sample results

 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494 8493

8. Simulation Results

Figure 16 shows the Elastic material response using Ls-Dyna. The results are not matching with the experimental
results. Figure 17 shows the displacement Vs force values of washer reaction in Ls-Dyna simulation. We studied the
software element stiffness behavior against the experimental results and tabulated in table. 2. The following figure
shows the ELFORM (-1,-2, 2, 3, 18) response.
Force (KN)

Force(KN)
Elform
0 2
Elform
(-1)

Displacement (mm) Displacement(mm)

Figure. 16 simulation force for Elastic Material Figure. 17 simulation force for different element formation

In this study the maximum load values was matching but stiffness behavior of the washer not matched with
simulation. Then the simulation is done by using different Element formation in Ls-Dyna .This study states that the
ELFORM 3 (fully integrated quadratic 8 node element with nodal rotations) and ELFORM 18 (8 point enhanced
strain solid element for linear statics only) stiffness behavior was close to the reality. The change in contact stiffness
(SOFT constraint) also gave similar result to the reality. There was a 26.5% variation in simulation result to the
experimental result. So element formation plays a vital role in the simulation to match with the experimental
behavior.
H.K.Dubey, Dr. D.V. Bhope, studied the (D/d) and (h/t) deflection pattern of simulation with the analytical
calculation. In this work we studied the non-standard design parameter behaviour as well as comparison of
simulation with experiment

Table. 2 simulation force for different element formation

Simulation # ELFORM FLAT REGION(mm) DISPLACEMENT(mm) FORCE (Ton)

3 33.6
1 -1 2
5 46.3
3 33.6
2 2 2
5 46.4
3 34
3 3 2
5 43
3 42
4 18 2
5 44

The Elform 3 model result is 20 % variation with the experimental results. In this Ls-Dyna model we changed the
contact stiffness behavior. We changed the contact stiffness nodal to segment surfaces behavior that results give the
15% error reduction. The final model with contact stiffness gave 95% closer results.
Figure 18 shows the comparison chart between the experimental result and simulation result for contact option
SOFT=2 (Segment based contact) in Ls-Dyna
8494 Shree Vishnu Raj et al., / Materials Today: Proceedings 5 (2018) 8486–8494

Force (KN)
Experiment
with SOFT…

Displacement (mm)
Figure. 18 comparison results for experimental and
simulation results

9. Conclusion

a. The washer design in this work showed to be able to withstand maximum of 45 tons without any permanent
set. Considering the 2mm flat region will provide the uniform load distribution.
b. The analytical model developed in this work presents stress results is good agreed to those calculated results
of finite element method
c. High thickness allows washer to withstand more load as well as increase in stiffness
d. Element formulation (3-fully integrated quadratic 8 node element with nodal rotation) for solid element in
Ls-Dyna with contact stiffness of SOFT constraint carries valuable response in element behavior
corresponding to the stiffness factor in simulation model towards reality
e. The stiffness of the washer in experiment was 11.33 tons/mm; initial simulated washer stiffness was 14.33
tons/mm with default element formation (2-fully integrated solid) in Ls-dyna.
f. The result variation between the experiment and simulation was 26.5%. After multiple iteration the
variation is became 5.9%.
g. From the above discussion the element stiffness in Ls-dyna giving similar result with segment based
contact.

Acknowledgment

Authors would like to thanks CTC- Corporate Technology Centre, Tube Investment of India, Chennai for the
financial support and grateful to other colleagues for their help in experiments.

References

[1] H.K.Dubey, Dr. D.V. Bhope, Stress and Deflection Analysis of Belleville Spring. IOSR Journal of Mechanical and Civil Engineering
(IOSRJMCE) ISSN: 2278-1684 Volume 2, Issue 5 (Sep-Oct 2012), PP 01-06
[2] Bhandari, V. B. (2010), Design of Machine Elements (3rd ed.), Tata McGraw-Hill, p. 441, ISBN 978-0-07-068179-8.
[3] Shigley, Joseph Edward; Mischke, Charles R.; Brown, Thomas H. (2004), Standard handbook of machine design (3rd ed.), McGraw-Hill
Professional, p. 640, ISBN 978-0-07-144164-3.
[4] Schremmer, G., "Endurance Strength and Optimum Dimensions of Belleville Springs," ASME-paper 68-WA/DE-9, 1968.
[5] http://www.spaenaur.com/pdf/sectionD/D44.pdf
[6] http://ftp.lstc.com/anonymous/outgoing/jday/manuals/DRAFT_Theory.pdf
[7]https://www.spirol.com/library/main_catalogs/SPIROL-Disc-Springs-us.pdf