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Yes, forgot to include the spring info. Spring I.D, is 0.488 and the O.D. is 0.812. I should also mention that the aluminum ferruel will not have full contact with the fender washer due to distortion as a result of crimping it to the wire rope. Thanks.Baluncore said:Failure of the washer will depend on the unspecified inside diameter of the helical spring.
If it isn't, just use 2 or 3 of them.nation99 said:You probably have guessed by now that I'm a DIYer and not an engineer. That being said, I do understand what you are suggesting is a possibility. Thus my original question...will the fender washer be stiff enough to maintain the load that it will see?
If you have ignored the obvious failure modes, and so build a house of cards, that design failure may later be investigated by a Coroner.nation99 said:Thus my original question...will the fender washer be stiff enough to maintain the load that it will see?
I believe that it will be stiff enough, but the assembly will not be stable, as mentioned above.nation99 said:... Thus my original question...will the fender washer be stiff enough to maintain the load that it will see?
@nation99 this would be a good approach. Maybe you or a friend has a lathe, these could be turned up in a matter of minutes. I would volunteer to do it for you but my lathe is out of service, I'm looking for a new motor...Baluncore said:I would design a stepped seat to replace the fender washer.
Thank you for your time and thoughts. The springs are plain and ground ends. I agree that installing a sleeve between the wire rope and the spring I.D. will add stability. All I want to do is to maintain tension on the wire rope and the spring is there to compensate for slight movement of the surrounding/supporting structure (treated wood). I'll continue looking for washers that may be a bit thicker. Thanks again!!Lnewqban said:I believe that it will be stiff enough, but the assembly will not be stable, as mentioned above.
I have created a scale drawing with the dimensions that you have provided.
Note how the magenta spring is free to move toward the right and go over the outside diameter of your washer.
At a glance, that washer is the only member of your assembly that looks marginally able to match the other beefy elements.
Another factor that may make things worse is the non-flat bottom of that heavy duty spring (if the spiral ends have not been squared and ground to be flat), which will transfer the load completely off-center to the washer, which will not remain horizontal.
Note how commercial spring hangers, rather than flat washers, have spring cups at both ends of the spring, in order to avoid the discussed problem.
As you don't have those metal cups, a simple rubber sleeve located inside the spring, having the proper OD and ID, could greatly help with stability.View attachment 333644
View attachment 333645
View attachment 333643
How much play are you expecting? @Baluncore has the right idea when he suggests a stack of Belleville washers for this amount of force.nation99 said:All I want to do is to maintain tension on the wire rope and the spring is there to compensate for slight movement of the surrounding/supporting structure (treated wood).
I chose this spring because it provides a range of tension that is appropriate for the application when it is at the mid range of travel which is 0.200"...0.400 from full length to solid length. Belleville washers would be a good option, but I think the cost of the washers required to get that amount of travel would be cost prohibitive.Nugatory said:How much play are you expecting? @Baluncore has the right idea when he suggests a stack of Belleville washers for this amount of force.
A fender washer is a flat washer with a particularly large outer diameter in proportion to its central hole. They are commonly used to distribute the load of a threaded fastener, like a screw or nut, over a larger area. In wire rope tension applications, fender washers help to distribute the stress exerted by the tensioned rope over a broader area, thereby reducing the risk of damage to the surface material and enhancing the stability of the connection.
To determine the adequate load capacity for a fender washer in wire rope applications, it's essential to consider factors such as the maximum load the wire rope will bear, the material of the washer, the environmental conditions (like corrosion potential), and the size of the washer relative to the bolt and mounting surface. Calculations should include the expected tension in the wire rope and the mechanical properties of the washer material, ensuring that the washer can handle the load without deforming or failing.
The best materials for fender washers in high-tension wire rope applications are typically those that offer high strength and corrosion resistance. Stainless steel is a common choice due to its durability and resistance to rust. For extremely high loads or harsh environments, alloy steels or specialized materials like titanium might be used. The choice of material also depends on factors like cost, availability, and specific environmental conditions.
Yes, the size of a fender washer significantly affects its performance in wire rope tension systems. A larger outer diameter will distribute the load over a greater area, reducing the pressure on the mounting surface and minimizing the risk of material deformation or failure. However, the thickness of the washer also plays a critical role in its ability to withstand the load without bending or breaking. Therefore, both the diameter and thickness should be optimized based on the specific requirements of the application.
Common signs of failure in fender washers used with wire rope include bending, cracking, rusting, and excessive wear. These can be mitigated by selecting the appropriate material and size of the washer for the expected loads and environmental conditions. Regular inspection and maintenance are also crucial to detect early signs of wear or corrosion and replace the washers before they fail. Additionally, using proper installation techniques to ensure even load distribution can help prevent premature washer failure.