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In order to reduce size of the final equipment and make it more cost effective, Original Equipment Manufacturers (OEM) are seriously looking at reducing the size of Disc Springs without affecting the Performance.

To address this growing market need and to manufacture high performance Disc Springs, offering higher fatigue life at higher stress levels, Gala has entered into technical tie-ups with globally renowned Aachen University of Germany. This tie-up has helped Gala to fine tune the raw material specifications, employ better heat treatment process and significantly improve on the processes which induct high level of residual compressive stresses, resulting in high performance Disc Springs.

This improved manufacturing technology involving Gala’s Proprietary Finishing Process has also helped Gala to optimize on the design of Disc Springs, so that for the same load/deflection requirement, Gala is able to offer small size Disc Springs resulting in substantial cost reduction for customers by way of reduction of their equipment dimensions.

Gala’s Proprietary Finishing Process ensures greater depth of the affected layer exhibiting alterations of the work hardening state and compressive residual stresses. It also ensures generation of glossy surfaces with low roughness as compared to shot peening. All this results in significantly enhancing the mechanical behavior of Disc Springs especially under cyclic / fatigue loading.

 

 
Parameters Standard Disc Spring Next Generation Disc Spring Change
Outsider Diameter 250mm 230mm -8%
Inside Diameter 127mm 127mm  
Thickness 7.5mm 7.05mm -6%
Overall Height 16mm 15.5mm -3%
Travel 6.1mm 6.1mm  
Fatigue Life 2 million cycles 2 million cycles  
Space Required 1000000 mm3 819950 mm3 -18%

* Result shall vary depending on applications & design

This comparison clearly highlights of 18% space reduction & hence considerable cost reduction for brake component in Hydraulic Motor Brake.