Materials for Springs

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1 Materials for Springs

2 Y. Yamada (chief Ed.) Materials for Springs Translated from the Japanese original edition published by JSSE Organized by JSSE translation committee With 336 Figures J S S E Japan Society of Spring Engineers

3 Dr. Eng. Yoshiro Yamada Dr., Professional eng. Japan in Metallurgy Yamada Research & Consultant Office Lecturer, Setsunan Univ. Japan Mr. Toshio Kuwabara General Affairs Director Japan Society of Spring Engineers (JSSE) MH-KIYA Building 3F 12, KANDA-MIKURACHO CHIYODA-KU, TOKYO JAPAN Library of Congress Control Number: ISBN Springer Berlin Heidelberg New York This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. Springer is a part of Springer Science+Business Media springer.com c Springer-Verlag Berlin Heidelberg 2007 The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Typesetting: by the authors and Integra using a springer LATEXmacro package Cover design: deblik, Berlin Printed on acid-free paper SPIN: /Integra

4 Foreword The Japan society of Spring Engineers, formerly called the Japan Society of Spring Research, was established in Thereafter, the society has endeavored to edit and publish many books on spring technologies. Among these publications, there have been such books as Bane in Japanese or Springs in English published in 1959, revised in 1964 and 1982, and Spring Design published in 1963, revised in Since then, various advanced materials and improved process technology have been developed. Reflecting the rapid development of PC hardware and software, we published FEM for springs, in 1997 for advanced spring design analyses. The book was later translated into English and published from the Springer publishing company in As for spring materials, Spring Materials and their characteristics (in Japanese) was published in The book Materials for Springs is the English version of this book with some additional information currently available in the latest Japanese material industry. I am confident that this book will provide a lot of advanced technical information on spring materials to engineers, researchers and students in worldwide spring industry. April 2007 Kosuke Nagaya Chairman, The Japan Society of Spring Engineers Professor, Dr., Gunma University, Japan

5 Preface to Japanese Edition Since the publication of the last edition of the book entitled Springs (written in Japanese) in 1982, extensive progresses have been made in all areas of spring materials technology. Publishing a new book on spring materials and the related technologies and adding information obtained in the twenty years after the last edition seem to be appropriate. This book is basically intended for engineers related to spring materials and technologies who graduated from metallurgical or mechanical engineering course in technical high school, or in other higher engineering schools, as well as those who are related to purchases or sales of spring materials. In the first chapter, the fundamental selection processes of spring materials and concomitant working processes including the information sources on materials database are given, followed by the basic mechanisms and theories of spring failures such as fatigue fracture, creep/stress relaxation and stress corrosion cracking of metallic materials. In the second chapter, ferrous and non-ferrous metallic materials are the main topics. In the third and fourth chapters, polymer materials, FRP (Fiber Reinforced Plastics), ceramics and C/C composite materials are the main subject respectively. In each chapter from the second to the fourth chapter, material grades belonging to each material category, their characteristics, production processes, and special cares to be taken of when actually using the materials for springs, are given. Spring design technologies are little included in this volume however, because they are separately dealt with in the fourth volume (in Japanese) in this publication series. In the fifth chapter, lists of Japanese spring material manufacturers and their material grades being produced, relative prices of some spring materials compared to standard materials in Japan, comparisons of spring materials in the Japanese Industrial Standards with some other foreign standards, etc, are summarized. It is to be remarked that the information on the relative prices of some spring materials in this chapter is not always applicable in any cases, since the price depends on various factors such as quantity of one time purchase, delivery condition, etc.

6 VIII Preface to Japanese Edition I express my feeling of great thanks to Mr. Yoshihide Nagai, a former director of the Japan Society of Spring Research and Mr. Kazuya Nakagawa, Nikkan Kogyo Shimbun Company, for their help for editing this book. January 2000 Yoshiro Yamada, Dr. Leader of the publication Working Group

7 Preface to the English Version In editing this English version, efforts were made to update the contents in the original Japanese edition such as Japanese Industrial Standard (JIS) specifications and some other information that was felt better to up-date. For full particulars of any national or international standard, the up-to-date edition should always be consulted. Since new information on delayed fracture of spring steels has been obtained, topics on delayed fracture and notch susceptibility of high strength steels in corrosive environments have been newly added at the end of the Chapter 1. It is hoped that readers of this English version will gain knowledge from this book in which the most advanced spring and spring material technologies are contained. Special thanks are due to Mr. Kanji Inoue, Senior Manager of NHK Spring Co. Ltd. for proof reading most part of the English translation manuscript and to Ms. Shimiko Shimamura, President of Plain Corporation for her efforts for preparing galley proofs. Acknowledgement is also given to Mr. Toshio Kuwabara, Director of the JSSE, for correspondence with the Springer Verlag Company for publishing this English edition and proof reading of Chapter 3, to Mr. Hiroshi Koyama for his important efforts to promote the activity throughout this project, and to all the engineers and researchers who participated in the English translation of this original Japanese book. April 2007 Yoshiro Yamada, Dr., Professional eng. Japan in Metallurgy Leader of the English Translation Committee in JSSE

8 Author Index Japanese Edition Authors (Organization belonged when published.) Tadasu Abumiya (Kobe Steel Ltd., Chap. 2.5) Hiroaki Hayashi (Suzuki Metal Industry Co. Ltd., Chap (2), (4), and 2.3) Hiroshi Horikawa (Furukawa Techno Materials Co. Ltd., Chap. 2.6) Tomohito Iikubo (Daido Steel Co. Ltd., Chap. 2.2) Hideaki Iwata (Tokai Rubber Industries Ltd., Chap. 3.2) Kenji Kanazawa (Chuo University, Chap ) Yutaka Maeda (MRC Techno Research Inc., Chap. 3.3) Teruyuki Murai & Akio Ikenaga (Sumitomo Electric Industries, Ltd., Chap (1)) Takao Nakagawa (Across Corporation, Chap. 4.2) Toshimasa Ochiai (NGK Industries, Chap 2.4.1, 2.4.2, 2.4.4, and 2.4.5) Ken Okabe (Harada Metal Industries, Chap ) Yasuhiro Oki & Nobuhiko Ibaraki (Kobe Steel Ltd., Chap (3) and (10) i) Masao Sakamoto (National Research Institute for Materials Sciences, Chap (3) and (4)) Shigemi Satoh (NHK Spring Co. Ltd., Chap. 4.1) Yatsuka Takata (Aichi Steel Corporation, Chap and 2.1.2) Yoshinori Tanimoto (Nippon Seisen Co. Ltd., Chap (3)) Akio Tsuzuki (Togo Seisakusho Corporation, Chap. 5) Katsuyuki Uchibori (Mitsubishi Steel Mfg. Co. Ltd., Chap (11)) Isao Ueda (Horikiri Industries, Chap (10) ii) Kyosuke Uemura (DuPont Kabushiki Kaisha, Chap. 3.1) Yoshiro Yamada (Suncall Corporation, Chap 1.1, 1.2.1, (1), (2), (1) viii)

9 XII Author Index English Translation Committee: Yoshiro Yamada, Committee Chief, Setsunan University Hiroshi Koyama, Committee sub-chief, Japan Society of Spring Engineers Kanji Inoue, Translation Supervisor, NHK Spring Co. Ltd. Toshio Kuwabara, Coordinator, Japan Society of Spring Engineers Abraham Mehari, Aichi Steel Corporation Nobuhiko Ibaraki, Kobe Steel Ltd. Teruyuki Murai, Sumitomo Electric Industries Ltd. Kenichi Shimizu, Sumitomo (SEI) Steel Wire Corp. Fumiaki Nozoe, Sumitomo (SEI) Steel Wire Corp. Akihiko Nishikawa, NHK Spring Co. Ltd. Tomohito Iikubo, Daido Steel Co. Ltd. Suguru Nomura, NHK Spring Co. Ltd.

10 Contents 1 A Guide to Spring Material Selection Introduction Functions and Qualities Required for Springs and the Spring MaterialSelection Basic Items to be considered in Spring Material Selection SpringMaterialSelectionMethod General Considerations of Spring Durability Supplements: Delayed Fracture of High Strength Steel and thetestingmethods DelayedFractureTestsofStraightBar TestingforHelicalSprings Metallic Material for Springs SteelMaterial Manufacturing Method of Steel Material for Springs Various Characteristics Required for Hot-Formed SpringSteel ColdFormedSprings HeatResistingMaterialforSprings Introduction Types of Heat Resisting Spring Material Manufacturing Process of Heat-Resisting Spring Material CharacteristicsofSuperalloy SpringCharacteristicsofSuperalloy Constant Modulus and High Modulus Spring Material Constant Modulus Spring Material HighModulusSpringMaterial CopperBaseAlloySpringMaterial GeneralRemarks Brass...270

11 XIV Contents PhosphorBronzeandNickelSilver Copper Beryllium OtherCopperAlloy TitaniumAlloysforSprings Resource and Refining Process of Titanium MeltingProcessofTitanium Forging, Rolling and Finishing of Titanium PhysicalPropertiesofTitanium PropertiesofTitaniumandTitaniumAlloys SpringCharacteristicofTitanium Ni Ti Shape Memory Alloys and Super-Elasticity GeneralPrinciples Manufacturing and Evaluation Method Applications Polymeric Materials Plastics Introduction Comparison of Typical Material Properties ConsiderationofShape Consideration of Fabrication ApplicationExamples InstructionforPlasticUse Rubber A Choice of Rubber Materials for Springs Compounding Ingredients Manufacturing Process of Anti-Vibration Component ExamplesofMolding Material Properties for Vibration Isolator Testing Methods for Rubber Vibration Isolators CompositeMaterials VariousFRPSprings Material Composition of FRP Spring ManufacturingProcessofFRPSpring MaterialPropertiesforDesign EvaluationofFRPSpringProducts TipsonFRPMaterials Inorganic Materials Ceramics CeramicsforSpring StrengthofCeramicSpring Operational Temperature of Ceramic Spring RCC(ReinforcedCarbon-Carbon) PropertiesofRCC...353

12 Contents XV Manufacturing Method and Material Characteristics ShapesandPropertiesofC/CSpring Appendix PriceofSpringMaterial Comparison between JIS and International Standards DataBooksforSpringMaterial MaterialManufacturersandProducts UnitConversionTable Index...373