light compression springs
When extension springs fail it is most often due to spring overstressing. Too much stress or force can cause the spring to break or set. So what causes overstressing to occur? In most cases, spring overstressing happens due to a design flaw. For example, an extension spring that is designed for strength will have very little elasticity. When stretched too wide, it becomes highly stressed and susceptible to breakage. The damage can happen at the spring body or at the spring ends.
An extension spring is most fragile and vulnerable at its ends. As the loops or hooks are formed, the wire is sharply bent upward. The sharp bend creates a significant concentration of stress. A correctly designed spring will take this concentration into account so as to prevent premature failure.
When an extension spring fails due to spring overstressing, it is likely the spring design needs to be adjusted. Some simple design changes can prevent overstressing and extension spring failure:
Increase the outer diameter
Decrease wire diameter
Add more coils by making the body length longer
When specifying extension springs, provide the spring manufacturer with the most detailed information as possible about the application. This should include details such as the necessary extended length and the required load or, in the case of spring replacement, the actual measurements of the existing extension spring.