Finite Element Analysis of Wave Springs : Enhancing Design Precision and Performance Reliability

In modern precision engineering, Wave Springs have become a key component for achieving compact yet reliable force control in mechanical assemblies. As industries increasingly demand smaller, lighter, and more efficient mechanisms, the design and validation of these springs must evolve beyond traditional empirical methods. Finite Element Analysis (FEA) offers an advanced, physics-based approach to predict and optimize spring behavior under real-world loading conditions.

The figure shown above illustrates a total deformation analysis of a single-turn Wave Spring under static compression, performed using ANSYS Structural simulation. Through this analysis, engineers can accurately visualize how the spring reacts to axial loading, enabling deeper insight into its performance, safety margin, and design optimization potential.

1. Simulation Objective and Setup

The main objective of this analysis is to evaluate the total deformation and stress distribution of the Wave Spring under a specified compression load. The spring geometry was modeled according to actual production dimensions, with careful attention to wave height, thickness, and number of waves per turn—factors that critically influence spring stiffness and deflection characteristics.

In the ANSYS Static Structural module, the lower contact surface was set as a fixed support, representing the stationary seat of the spring. The upper plate applied a uniform downward displacement, simulating the working compression that occurs in an assembled mechanism, such as a rotary vane pump, mechanical seal, or aerospace actuator. The contact between the Wave Spring and the parallel plates was defined as frictionless to focus purely on elastic deformation and material response.

Material properties were defined based on stainless steel (SUS304), with an elastic modulus of 193 GPa and Poisson’s ratio of 0.3. These parameters accurately represent the typical materials used in high-performance Wave Springs, ensuring that simulation results reflect real-world behavior.

2. Total Deformation and Structural Response

As indicated in the deformation contour plot, the maximum displacement reached approximately 3.35 mm, while the minimum deformation was near 0.0003 mm, localized at constrained contact zones. The wave crests exhibited the highest deflection, as expected, while the valleys—supported by the contact surfaces—remained relatively stable.

This deformation pattern demonstrates the Wave Spring’s ability to store potential energy efficiently within a very small axial space. The nonlinear load–deflection relationship characteristic of Wave Springs can also be inferred from the FEA results, providing engineers with valuable data for system-level load calibration.

Moreover, the simulation confirms uniform deformation distribution along the circumferential direction, indicating excellent symmetry and load sharing. This ensures consistent force output and minimizes uneven stress that could lead to early fatigue failure.

3. Stress Analysis and Safety Considerations

Beyond total deformation, the stress results (not shown here but analyzed in the same model) reveal how local bending and compression interact at each wave crest. The maximum von Mises stress typically occurs at the inner radius of the crest, where bending curvature is greatest. Understanding this stress concentration is crucial for determining the spring’s fatigue life and safety factor.

By running iterative simulations, engineers can compare alternative Wave Spring designs—adjusting parameters such as:

• Wave height and amplitude

• Material thickness

• Number of turns or nested layers

• Contact surface conditions

Through such optimization, it becomes possible to balance deflection range, load capacity, and fatigue resistance with high precision. This analytical approach eliminates excessive prototyping, reduces development time, and ensures that the final product meets both mechanical and cost-performance targets.

4. Benefits of FEA in Wave Spring Design

Finite Element Analysis has transformed how Wave Springs are designed and validated. Its advantages include:

• Accurate prediction of real behavior
  FEA allows precise estimation of deformation, stiffness, and stress distribution before manufacturing, reducing trial-and-error design.

• Material and geometry optimization
  Engineers can experiment virtually with different materials or geometrical profiles to achieve optimal performance under various load conditions.

• Improved product reliability
  By identifying potential weak points or overstressed areas, design engineers can reinforce critical regions, ensuring longer service life and operational safety.

• Reduced development cost and time
  Virtual testing accelerates design validation, cutting down the need for physical prototypes and expensive laboratory tests.

• Enhanced customer confidence
  The ability to present simulated performance data demonstrates strong engineering capability, strengthening technical communication with customers and partners.

5. Application Examples

Wave Springs designed and analyzed through FEA are now widely applied across demanding industries:

• Rotary Vane Pumps – used to maintain precise preloading on rotor components, improving sealing efficiency and reducing vibration.

• Mechanical Seals – ensuring uniform sealing pressure and compensating for axial movement under varying thermal conditions.

• Medical Devices – where compactness and consistent load characteristics are essential for precision instruments such as staplers or ultrasonic scalpels.

• Aerospace Systems – offering lightweight, space-saving solutions without compromising fatigue strength.

• Energy and Oil & Gas Equipment – maintaining stable operation under high pressure and temperature variations.

Each of these applications benefits from FEA-driven design verification, ensuring that every spring performs reliably even in harsh or safety-critical environments.

6. From Simulation to Production

At Zhejiang Lisheng Spring Co., Ltd., simulation is not just an academic tool—it is a core part of our product development process. Every new Wave Spring design undergoes detailed FEA verification before tool manufacturing and production. Combined with our advanced CNC forming and heat-treatment processes, we guarantee that each spring leaving our factory meets the highest international standards for precision and durability.

By integrating digital engineering tools like ANSYS with decades of spring manufacturing experience, we bridge the gap between virtual modeling and real-world performance. The result is a new level of reliability and consistency that our customers across automotive, medical, and industrial sectors can depend on.

7. Conclusion

Finite Element Analysis empowers engineers to see beyond what traditional calculation methods can offer. The total deformation plot shown above is more than just a colorful image—it represents a precise, data-driven approach to designing the next generation of compact, high-performance Wave Springs.

Through the continuous application of FEA in our R&D process, we ensure that every Wave Spring is optimized not only for strength and deflection but also for long-term reliability and efficiency. This commitment to engineering excellence defines our mission: to deliver compact solutions that move the world forward—one wave at a time.