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Assembled Extension
Spring for the Automotive
Industry

Assembled Extension Spring for the Automotive Industry

(click on thumbnail to enlarge)

At Sterling Spring, LLC, we manufacture 400,000 to 600,000 of this automotive release spring annually. This high volume project exemplifies our wide array of manufacturing, assembling and metal finishing capabilities.

The springs located on both ends are made out of .192" phos music wire, are coiled and looped on one of our shop's many CNC machines and are shot peened in-house to improve the cycle life. The connecting rod is manufactured out of .187" basic wire on custom tooling built for our Fourslide equipment.

We developed and fabricated a special punch press tool to fully automate the assembly and inspection of the final product. Our automation not only securely fastens the middle rod to the two springs and ensures a high quality product but also greatly improves our manufacturing efficiency to lower labor costs which is passed onto the customer to help their bottom line. The assembly is then run through our paint line and then carefully packaged to ensure parts arrive safely and ready for our customer's production line.

  Click to enlarge
Assembled Extension Spring for the Automotive Industry

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This spring is not a run-of-the-mill part that any spring company can manufacture. All of the manufacturing processes used are available in-house at Sterling Spring which allows us to control costs, reduce lead times, and provide our customers with diverse products for almost any spring application. To learn more about this project, or our other capabilities, see the table below or contact us directly.


Assembled Extension Spring- Project Details

Product Description This Release Spring is used on a truck application.
Precision Wire Forming Capabilities Applied/Processes
Primary:
Coiling (Spring)
Looping (Spring)
FourslideWire Form (Rod)
Custom tool designed and built in-house (Rod)
Assembling Process - 2 springs and 1 Rod
Automated Assembling - custom punch press tooling
Secondary:
Stress Relieving (In-House)
Shot Peening (In-House)
Painting - Gray Enamel (In-House)
Equipment Used to Manufacture Part
#3 Spring Coiler (Spring)
Looper (Spring)
Calibrated Oven
Fourslide(Rod)
Shot Peener (Spring)
In-House Paint Line (Assembly)
Punch Press (Assembly)
Automation (Assembly)
Calibrated Measurement Gauges
Quality Control Equipment
Overall Part Dimensions
Length Inside Hooks: 10.720" to 10.900" (Assembled)
O.D.: ø 1.12" ± 0.015 (Spring)
Wire Size: 0.192" (Spring)
Wire Size: .0187" (Rod)
Tightest Tolerances +/- .015"
+/- 3 degrees
Material Used
.192 Phosphate Music Wire (Spring)
ASTM A228 (Spring)
.187 Basic Wire 1008/1010 (Rod)
ASTM A510 (Rod)
Material Finish Shot Peen
Gray Enamel
In process testing/inspection performed
Outside Diameter (Spring)
Overall Length (Rod)
Length Inside Hooks (Assembly)
Operating Load (Assembly)
Multiple Length and Dimension Gauges Utilized
Industry for Use Automotive Industry
Volume 400,000 - 600,000/Year
Delivery/Turnaround Time Weekly Releases
Delivery Location Kentucky
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Release Spring

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