SUNZO's precision-engineered disc springs are tailored to your exact application requirements through a structured six-phase workflow. Our ISO 9001:2015 certified process ensures optimal performance and reliability for your specific needs.

Our application engineers conduct comprehensive requirements analysis, capturing critical parameters including:

• Dynamic load profiles (static/dynamic force up to 50 kN)
• Deflection limits (0.1-15 mm)
• Operating temperature range (-270°C to 650°C)
• Environmental exposure (corrosive media, radiation, vibration)
• Dimensional constraints (outer diameter 6-200 mm)

Our design phase employs advanced Finite Element Analysis (FEA) using ANSYS software to simulate:

• Stress distribution and fatigue life (up to 10⁹ cycles)
• Load-deflection characteristics under thermal and mechanical cycling
• Geometric optimization including dish height-to-thickness ratio (0.4-1.2)
• Cone angle optimization (12°-18°) and edge radius (0.2-0.8 mm)
• Target stiffness achievement (5-50 N/mm) and non-linear force behavior

Prototype validation utilizes CNC precision stamping (tolerance ±0.02 mm) and proprietary heat treatment processes. Comprehensive testing per ISO 16148 standards includes:

• Load-deflection curve verification
• Hardness testing (HRC 42-52)
• Microstructural analysis via metallographic examination

Production runs leverage automated manufacturing cells with real-time SPC monitoring. Surface treatment options include:

• Zinc phosphate (500-hour salt spray resistance)
• Dacromet coating (1,500-hour corrosion protection)
• Electroless nickel plating (FDA-compliant applications)

Each component receives laser marking with unique serial number for full traceability from raw material certification to final inspection data.

Quality validation includes 100% dimensional inspection using CMM (0.001 mm resolution), ultrasonic flaw detection, and batch testing for fatigue life (per DIN 2092). Custom testing protocols available for specialized applications.

Final delivery includes comprehensive documentation: material certificates (EN 10204 3.1), test reports, and FEA simulation data. Our technical support team provides installation guidance and performance monitoring recommendations.