Development and analysis of polymer-based wave spring response with different infill density

Abstract

Abstract The development of wave spring has enhanced performance characteristics like load bearing capability, stiffness, energy absorption and energy release technique in a constrained space. The wave springs can be developed by considering the number of turns, waves, thickness, which can be easily adjusted to accommodate stronger force and to meet specific technical requirements as per the area of applications. Wave springs are complex in design and can be fabricated by additive manufacturing technique. Advanced manufacturing methods provides full design freedom to develop the wave spring of various geometry. Present work is focused to evaluate the Polypropylene wave spring stiffness and its load bearing capacity, which may be helpful in the application of smooth landing of drones and robotic structures, mechanical pressure valves and washers. Limited study of the polymer-based wave spring properties and its material behavior has been studied. The contemporary work establishes the computational and experimental analysis of crest-to-crest wave springs which are designed with honeycomb infill pattern with infill density of 100%, 90% and 80%. Maximum load bearing capacity and stiffness of the different designed wave springs are obtained through universal testing machine. From the experimental results the average load bearing capacity of PP 100%, PP 90% and PP 80% at 75% of compressible distance of crest-to-crest wave spring from cycle 1 to 10. The results of the 1st cycle load bearing capacity are 234.075 N, 181.31 N and 178.58N respectively.