MAIN GOALS
The technologies to be studied by this project include:
Enhanced scientific knowledge of residual and applied stresses.
“Next generation” software design tools, integral to CAD/FEA and MKS.
New innovative software packages and prediction models for improving spring designs and ensuring optimum material selection.
A prototype system making use of advanced camera and stroboscopic technologies to quantify dynamic deflections.
A prototype adapted X-ray machine for residual stress analysis.
The above will result in a standard, comprehensive, innovative and affordable “toolkit” which will be made available to SMEs involved in spring manufacture across Europe.
TECHNICAL APPROACH
The following specific case studies have been created as a result of the project:
Compression spring end coil failures.
Springs operating in the extension and compression mode.
Sub-surface fatigue failures without inclusions.
Factors affecting end hook failures in extension springs.
Effect of prestressing on compression spring fatigue performance.
Stress profile in compression springs made from wire larger than 6mm.
Effect of speed of production on spring dimensions and load.
Effect of speed of testing on fatigue performance.
Effect of stress relief time on fatigue performance.
Factors affecting the fatigue performance of torsion springs.
Effect of coiling method on spring properties.
Stress analysis in springs made from strip.
Appearance due to shot peening.
The provision of the individual case studies will be followed by two full project consortium events and one-off individual (SME) company knowledge transfer event and secondments from R&D performers to each SME partner for a period sufficient to ensure they fully understand the needs of the spring manufacturers.
EXPECTED ACHIEVEMENTS
The development of new innovative spring software design, material selection and modelling technology will create an additional 960 jobs over 5 years. Clearly, in the short term the project will safeguard existing employment.
We estimate that the project will lead to European manufacture and substitution of high technology springs for the high technology sectors within Partner Countries. This will be targeted at aerospace, automotive, railway/rapid light transit, electrical, electronic and medical and healthcare (for the elderly).
We estimate that we will optimise spring designs and thereby reduce materials use by up to 20%, saving up to 12,000 tonnes of steel.
We estimate that the cost savings in the manufacturing of springs (all types) using our new technology will reduce manufacturing costs and a market price by about 7%.
The reduced material costs and improved manufacturing efficiency will reduce energy consumption, and greenhouse gases by 7%.