Belleville washers

Belleville washers, technically known as conical disc springs, are robust, washer-shaped components with a slightly tapered profile designed to support high compressive loads with minimal deflection in compact spaces. They store potential energy by flattening under load and are renowned for their ability to deliver substantial force with very little travel.
Design and Function
The unique design of Belleville washers allows for versatile performance characteristics.
High Load Capacity: They can handle much greater forces than standard flat washers or coiled springs of similar size, making them ideal for heavy-duty applications.
Minimal Deflection: They are the preferred solution when a strong spring force is required but the available movement (deflection) is limited.
Customizable Force Curves: The relationship between the applied load and the resulting deflection is highly predictable and can be tailored by adjusting the disc's geometry (height, thickness, and diameters).
Stacking Versatility: Multiple washers can be stacked in various configurations to achieve specific performance goals:
Series Stacking (alternating orientation): Increases the total amount of deflection for a given load.
Parallel Stacking (same orientation): Increases the total load capacity for a given deflection.
Combination Stacking: Allows engineers to create custom, non-linear force curves to suit complex application requirements.
Materials
Belleville washers are made from high-strength, durable materials to ensure long fatigue life and performance in demanding environments.
Chrome Vanadium Steel (50CrV4 / AISI 6150): The most widely used material, known for exceptional strength, toughness, and excellent fatigue resistance.
High Carbon Steel (CK75 / SAE 1070): A general-purpose, economical choice with good strength for thinner springs (under 1.25 mm thickness).
Stainless Steel (e.g., Type 302, 316, 17-7PH): Offers superior corrosion resistance and performs well across a wide range of temperatures, ideal for medical, marine, or food processing applications.
Specialty Alloys (e.g., Inconel 718): Used for extreme temperature (high or cryogenic) or highly corrosive environments.
Common Applications
Due to their ability to provide high force in a small, reliable package, Belleville washers are essential components in numerous critical industries.
Fastening Systems (Bolt Preloading): Their most common application, where they maintain precise tension in bolted joints, preventing loosening due to vibration, thermal expansion, or stress relaxation.
Automotive Industry: Used in clutch and brake mechanisms, engine valve systems, and suspension components to absorb shock and maintain tension.
Industrial Machinery: Employed in heavy presses, pumps, and gearboxes for load balancing, vibration isolation, and shock absorption.
Power Generation & Valves: Used in safety valves, pressure regulators, and switches for reliable operation under high-pressure conditions.