Additive Manufacturing and Damping Characterization of Wave Springs: Numerical and Experimental Approach

Abstract

Additive manufacturing (AM) enables the production of complex geometries that are challenging to achieve with traditional manufacturing methods. Wave springs, developed using AM, offer superior load-bearing capacity, lightweight structure, high energy absorption efficiency, and enhanced stiffness compared to conventional helical springs, making them ideal for advanced engineering applications. This research examines the dynamic behavior of AM-fabricated wave springs, with a focus on their potential for vibration isolation and energy absorption. Employing a combination of finite element analysis (FEA) and experimental testing, the study evaluates the effects of geometric variations on the damping characteristics and natural frequencies of the wave springs. The findings reveal how AM enables the creation of wave springs with customized dynamic properties, offering advantages in optimizing performance for specific applications and functional requirements. The results indicate that the rectangular wave spring design exhibited a damping ratio approximately 38% higher than the round design and 12% greater than the variable thickness design. Additionally, the study examines the fatigue resistance of AM-fabricated wave springs for all designs, assessing their durability under repeated loading conditions. It further revealed a trade-off between resonance frequency and durability, with the rectangular design achieving the highest fatigue life. By demonstrating the potential of AM to produce wave springs with tailored dynamic properties, this research contributes to sustainable industrial innovation.