Suspension spring manufacturing: How it's made – Lesjofors

Introduction to suspension springs and their role in vehicles

Compression springs are the main automotive spring type for delivering the suspension required across multiple transportation methods. Delivering comfort and control, the suspension spring is the link between the driver and the road, absorbing surface irregularities and preventing shocks and vibrations. Coil spring suspension requirements are different for every vehicle and deliver different performance levels subject to the compression spring design, rate of pitch, material and spring manufacture.

We have been a key global supplier of quality coil spring suspension to the automotive aftermarket for decades, providing unmatched expertise across the engineering of the car suspension spring for nearly every model and make of car.

Our unparalleled expertise has also secured suspension coil spring supply to every vehicle from freight trucks to road sweepers, from pick ups to trailers to buses and quad bikes and everything in between.

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How suspension springs work and their role in the suspension system

A suspension spring needs to not only provide precision driving and comfort but it also needs to deliver a load capability, supporting added weight without disproportionate slack. The suspension coil spring stores the force in the spring&#;s deflection, preventing the impact of the surface on the quality of the drive. High performance vehicles have very different demands to domestic cars. Superbikes have completely differing needs to that of Motorcycle Enduro racing, performance cars have differing needs to karting and rally cars.

This is why our engineers work with the best R&D teams for some of the biggest automotive brands and best race houses in world, developing exceptional coil spring suspension to suit every need.

Suspension springs in vehicle handling and comfort

Whole suspension systems are designed to operate in harmony. Depending on the vehicle type and intended market, the suspension coil spring, along with the engine and braking, all contribute to the desired type of handling experience. From gentle cruising in a large comfortable saloon unable to tell if you&#;re on gravel or silk, to hard cornering and a blistering grip that really allows some spirited handling - the strength of the suspension spring lies at the heart of the performance.

How suspension springs absorb and distribute shock from the road

In their installed state, suspension springs contain a huge amount of potential energy. As a vehicle travels and encounters bumps in the road, these forces push the wheel up and away from the surface. Suspension springs work by absorbing the shock and giving the opposite force in response. This means that the shock is not felt in the vehicle and the majority of the interaction happens in the suspension system &#; not impacting on the driver.

The relationship between suspension springs and other suspension components

Suspension springs work closest with the shock absorber. A shock absorber is a spring damper, stopping the suspension coil spring from cycling between compression and extension excessively. This allows the spring to take the shock by planting the wheel firmly back on the road. Suspension springs dictate the ride height of a car and a failed or worn spring can misalign the whole geometry of the system. Wheel camber can be affected, causing uneven tyre wear and drifted steering.

The role of suspension spring rate in vehicle performance

As a vehicle&#;s speed increases, so do the forces involved on the road. A big luxury saloon car built for comfort wants a soft ride and lower spring rate, ironing out all the ripples of the road and giving maximum passenger comfort. Conversely, a sports car wants a harder/higher spring rate. This transfers maximum feel and grip to the driver, at the expense of ride comfort.

The effects of suspension spring stiffness and damping on vehicle handling

Take a sports car for example - when the tyre encounters any undulating surface, the wheel wants to move in the opposite direction. With no suspension spring coil in place this force would transfer through the whole of the car and probably result in the wheel temporarily losing contact with the ground completely. This results in loss of grip/drive and in worst circumstances, complete control of the vehicle. 

The vehicle geometry and centre of gravity is also shifted, creating an unpredictable driving experience. With a suspension spring and damper in place, the force is absorbed and then the tyre with the full weight of the vehicle is returned to the ground. A stiffer suspension will return the tyre back to &#;normal&#; quicker but at the expense of allowing more of the force to travel into the vehicle. The opposite applies to a softer suspension set up. Better ride comfort but reduced grip. Matching spring stiffness and damper stiffness is important, the two work together and if mismatched, will not perform correctly.

The importance of regular maintenance and inspection of suspension springs

Suspension springs are in a vulnerable position and damage can occur that could lead to failure. It&#;s important to notice any corrosion or strange sounds originating from the suspension and if a broken suspension spring needs to be replaced, they must be done in pairs as springs will relax over time. They need to match to keep the geometry and ride height even.

Consequences of neglecting suspension spring maintenance

Surface damage is the number one cause of a broken suspension spring. If allowed to corrode, the material will weaken and possibly snap. Depending on the location this could mean spring debris fouling the bodywork or worst still, the tyre.

Regular inspections in identifying potential problems

Inspect the surface condition for corrosion and damage. Check the vehicle ride height is even. Do this by measuring the distance from the floor to the highest part of the wheel arch. 

This measurement should be even on both sides of the axel. If it isn&#;t, this could indicate that you have a broken suspension spring or other failed suspension spring component.

Common maintenance tasks for suspension springs, such as cleaning and lubrication

Coil suspension springs in situ contain an intense amount of potential energy. They should not be interfered with unless done so by a professional.

Importance of replacing worn or damaged suspension springs

If a suspension spring is worn or damaged, the overall vehicle geometry will be wrong. At best this means that the driving experience will be impaired. The vehicle may experience uneven tyre wear and handling issues. At worst, a damaged suspension spring may fail and throw a piece of shrapnel through your tyre at 70mph causing a catastrophic blow out.

Benefits of regular suspension spring maintenance, such as improved safety and performance

Regular suspension coil spring inspections will no doubt increase safety by highlighting any issues before they become dangerous problems.

Common problems and potential solutions for suspension spring issues

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Worn or broken suspension springs

Misaligned or bent suspension springs

Leaking or damaged shock absorber seals

Worn or damaged suspension spring mounts

Potential solutions for these issues, such as replacement, repair or adjustment

Always replace a broken, worn out or damaged component.

The future of suspension spring technology and potential advancements

The basic principle of suspension springs has remained the same since its inception.
However, advancements are being made all the time. Extensive material research and
developments are allowing more and more advanced design programs to create plans for
highly efficient suspension springs that push the boundaries of accepted convention.
Adaptive components will also be more commonplace. Adjustable suspension performance
isn&#;t new but we can see real time adaptive suspensions becoming more commonplace.
Imagine a vehicle that can &#;see&#; the upcoming pothole and adjust itself accordingly to
reduce shock and possible damage.

Improved materials and designs for suspension springs

Alloy steels offer the current optimal material for suspension springs. Work on polymer
springs is ongoing but still in its infancy. With increasingly powerful design programs we can
now accurately model progressive, dual and even triple-rate springs that work within
complex systems.

With our dedicated material scientists, there are very few metal spring materials we can&#;t
access or work with, and we hold one of the largest global stocks of chrome silicon and
chrome vanadium wire anywhere in the world.

We also work with a diverse range of steels, copper and titanium alloys, as well as super
alloys, including Inconel, Hastelloy and Nimonic.

More efficient and lightweight suspension spring systems

With material and design advancements, we are always striving to reduce compression
spring mass but not at the cost of the suspension spring performance.
We have a number of projects focused on gaining greater efficiencies in suspension across
the motorsport industry.

Research and development in advancing suspension spring technology

It is our privilege to work with R&D departments across recognised brands within the
automotive and car and motorbike racing industry. They are at the forefront of testing
advanced vehicular suspension spring technology and our design, material testing
laboratories and advanced manufacturing techniques help enhance the suspension spring
further.

We have a host of ongoing internal projects, all looking to advance R&D of spring
technology and we work closely with the Institute of Spring Technology to achieve these
goals.

Conclusion and key takeaways for understanding suspension springs

The suspension spring has been an integral part of vehicular drive success since the s. It
will always be a key component of nearly every transport method and its design heritage
will always advance as the demands in vehicular manufacture advance.

As a key coil spring suspension manufacturer we look forward to continuing our lead role
fulfilling the world&#;s suspension spring demands.

For more replacing the coil springinformation, please contact us. We will provide professional answers.