Finite Element Study on Forming Helical Springs by Wire Bending with a Plate

Abstract

Coil springs, widely used as mechanical elements, will enter another new production outlook due to the application of CNC wire bending machines and as the era of On-Demand Manufacturing is approaching. This article tries to follow the trend and use finite element analysis investigating parameters, such as the angle, shift distance, and wire diameter, applied in a CNC bending machine with a swivel plate as the die on the formed cylindrical helical coil springs. The results show that the angle of the swivel plate normal to the wire feeding direction and shift distance have a significant effect on the spring diameter, while the wire diameter has a significant effect on the spring pitch. The result will be used as a reference for the industry to develop On-Demand Manufacturing machinery applications in the future.