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3 Applications of Nitrogen Gas Springs in Automobile Stamping Dies

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Estimated reading time: 6 minutes

The nitrogen gas spring is an elastic component with nitrogen gas as the gas source. It is gradually replacing springs, rubber, air cushion, and other elastic elements with the advantages of stable elastic force, small volume, reliable working performance, and long service life. The use of nitrogen gas springs in stamping dies can reduce the volume of the die, shorten the manufacturing time, reduce the number of die trials and improve the success rate, prolong the life of the die, and can greatly improve the product quality and yield, and have high economic benefits. It is widely used in various fields such as metal stamping, forming, automobile manufacturing, injection mold, machinery, and equipment manufacturing.

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1.  How to Replace Die Springs with Nitrogen Gas Springs?

  • Deterministic Force requirements

If you know the amount of force required, just use that number when choosing a gas spring. If the total force required by the application is not known, the force provided by the die spring in the stamping die can be calculated. Determine whether the force required to perform the operation is the initial force (preload) or the final force (full range). Once determined, the total force required can be calculated. The most common way to find die spring force is to refer to the manufacturer’s force diagram.

To use the chart, you must know the size, color, preload of the coil spring, and how far it travels in the die. Load cells can also be used to determine to die spring force.

  • Calculate Gas Springs Numbers

Gas springs come in all popular die spring sizes, to determine how many gas springs you need, divide the total force by the maximum force available at that diameter. In most cases, fewer gas springs are required to meet force requirements. However, the force must be evenly distributed over the pressure pad, and more gas springs with less force may be required to balance the pressure in the stamping dies.

Figure 2 Gas spring of stamping die
Figure 2 Gas spring of stamping die
  • Choose Gas Spring Stroke Length

The last factor to consider when choosing a gas spring is stroke length. To choose the correct gas spring stroke length, first determine how far the die spring will travel in the die. Increase the die spring travel by at least 10% and choose a gas spring travel length equal to or greater than this number.

Example: Coil spring with 5″ (127mm) free length, 0.75″ (19mm) preload, and 0.75″ (19mm) travel in the die. Increase the coil spring travel by 10% to determine the minimum gas spring travel length. Minimum stroke length = 0.75″ (19mm) + (0.75″ (19mm) x 10%) = .825″ (21mm). Once the minimum gas spring stroke length is determined, the specific stroke length that best suits the space requirements can be selected.

Figure 3 Gas spring of stamping die
Figure 3 Gas spring of stamping die

2. Install Gas Spring

In most applications, gas springs can be easily installed in the same cored pockets as coil springs. Just make sure the bottom of the pocket is flat and the side of the hole is at right angles to the pressure pad. The pocket depth should be at least 50% of the length of the gas spring canister, or at least 1.25 inches (32 mm), whichever is greater.

The pressure pad should have a smooth area to allow the gas spring rod to make contact and should maintain contact with the air pad throughout the stroke. In some applications, gas spring mounting options such as attachable flange mounts, threaded holes, and thread patterns in the bottom of the cylinder can be utilized.

These options provide greater flexibility for using gas springs in existing molds. If the size of the selected gas spring does not match the coil spring to be replaced, there are simple steps you can take before installing the gas spring. If the gas spring is smaller than the coil spring, a spacer or sleeve can be used in the bag, or the gas spring can be flanged in place.

If the existing pocket is too shallow, it may have a deeper core, or a gas spring could be preloaded to meet space requirements. When coring gas spring installations, maintain a clearance of .02 to .04 inches (0.5 to 1.0 mm) from the diameter of the gas spring.

When installing a gas spring, the final consideration is the use of fluid in the mold. Direct contact with specific mold lubricants, coolants, and cleaners can be harmful to gas springs and should be avoided.

Figure 4 Gas spring of stamping die
Figure 4 Gas spring of stamping die

3. Summary of Experience in Installing Nitrogen Gas Springs

  • When the nitrogen gas spring is deflated, turn it upside down and press it lightly with an Allen wrench, otherwise, the valve core will be damaged and a large amount of cylinder oil will be sprayed out. When taking out the valve core, it needs to be unscrewed slowly to prevent the gas spring components from being damaged by violent disassembly.
  • When connecting in series, it is necessary to find the corresponding parts of the mold according to the drawings. After confirming the installation space, the joints and pipelines can be connected according to the drawings. If the pipelines are too long or the joints are wrongly connected, you can measure the distance with tools such as rulers. Change the connections alternately.
  • Suppose the nitrogen bottleneck is full of nitrogen after the equipment is connected, but the pressure gauge has no degree. In that case, you should first confirm whether the taps at the nitrogen bottle interface are suitable, and then check whether the air inlet connector is tightened. The interface must be completely aligned with the device, as long as the barometer has degrees, it can be used normally.

Springs are mechanical components designed to store and release mechanical energy. They are widely used in various applications across industries due to their ability to absorb shock, maintain tension, store energy, and provide flexibility. Here are some key aspects of springs:

Types of Springs:

Compression Springs: These springs are designed to absorb and store energy when subjected to compressive loads.
Extension Springs: Extension springs stretch under load and store energy in the process. They are commonly used to create tension.
Torsion Springs: Torsion springs operate by twisting around an axis when torque is applied. They store energy in the form of rotational motion.
Flat Springs: These are typically flat strips of material that bend or flex when force is applied. They are used in applications where space is limited.

Springs are made from various materials, including high-carbon steel, stainless steel, alloys, and non-metallic materials like plastics.
Material selection depends on factors such as required strength, corrosion resistance, temperature tolerance, and cost.
Design Considerations:

Parameters like wire diameter, coil diameter, number of coils, and spring length are critical in spring design.
Design factors also include load requirements, deflection limits, stress levels, and environmental conditions.

Springs find applications in automotive, aerospace, industrial equipment, consumer goods, electronics, and more.
Examples include suspension systems, brakes, valves, clutches, switches, toys, and tools.
Manufacturing Processes:

Springs can be manufactured through various processes, including coiling, winding, forming, and stamping.
Advanced techniques like CNC coiling and automated production lines ensure high precision and consistency.
Testing and Quality Control:

Springs undergo rigorous testing to ensure they meet performance and safety standards.
Tests include load testing, fatigue testing, dimensional checks, and material analysis.
Maintenance and Service Life:

Proper maintenance is essential to maximize the service life of springs.
Factors affecting service life include material fatigue, stress relaxation, corrosion, and overloading.
Specialized Springs:

Some springs are designed for specific applications, such as those requiring high temperatures (e.g., engine valve springs) or corrosive environments (e.g., marine applications).
Custom springs may be designed to meet unique requirements not satisfied by standard off-the-shelf options.
In essence, springs are versatile components that play crucial roles in numerous mechanical systems, offering flexibility, energy storage, and resilience to mechanical forces. Their design, material selection, and manufacturing processes are tailored to meet specific application needs, ensuring reliable performance across various industries.

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2 thoughts on “3 Applications of Nitrogen Gas Springs in Automobile Stamping Dies

  1. Abdula says:

    That sounds quite professional!
    Do you have such molds?

    1. Wendy says:

      Yes, we have the molds.
      Could you please send me your mail address?

      I can quote for you soon!

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