METHOD OF MANUFACTURING V-SHAPED SPRINGS OF ELASTIC COUPLINGS

Abstract

The paper considers a method for manufacturing V-shaped springs used in elastic couplings operating under dynamic loading conditions. Existing designs of elastic couplings and manufacturing technologies for complex-shaped springs are analyzed. The main drawbacks of known methods are identified, particularly the impossibility of forming V-shaped springs of a specific profile using conventional punch-and-die techniques. A new manufacturing method is proposed, based on simultaneous rotation of profiled punches, which ensures accurate formation of the spring geometry. A formula for determining the blank length is presented and justified based on geometric and technological considerations. An analytical dependence for determining the length of the workpiece was obtained, which takes into account the geometry of the spring and the influence of the material thickness, which allows to reduce the error in selecting the length of the workpiece compared to empirical methods.
The stress-strain state during bending was analyzed, it was found that with a decrease in the bending radius, deformations increase nonlinearly, and the introduction of a roller increases the effective bending radius and reduces maximum deformations. It was shown that the use of rollers in the bending zone reduces the risk of crack formation, reduces local hardening and stabilizes the forming process. The effect of elastic unloading was established, which can lead to an angle error of up to 2–5° for steels, which must be taken into account when designing the tool.
Additionally, a calculation model is proposed to determine deformation parameters and stress distribution during forming. The study shows that the use of rotational punches allows reducing internal stresses and improving dimensional accuracy compared to traditional forming methods.
The proposed method simplifies the manufacturing process and expands technological capabilities for producing springs of complex geometry. The results can be applied in mechanical engineering, particularly in the design and production of elastic couplings and other dynamically loaded elements.