Belleville washer

3 Articles

What’s In A Washer?

May 12, 2025 by 14 Comments

Some things are so common you forget about them. How often do you think about an ordinary resistor, for example? Yet if you have a bad resistor, you’ll find it can be a big problem. Plus, how can you really understand electronics if you don’t know all the subtle details of a resistor? In the mechanical world, you could make the same arguments about the washer, and [New Mind] is ready to explain the history and the gory details of using washers in a recent video that you can see below.

The simple answer is that washers allow a bolt to fit in a hole otherwise too large, but that’s only a small part of the story. Technically, what you are really doing is distributing the load of a threaded fastener. However, washers can also act as spacers or springs. Some washers can lock, and some indicate various things like wear or preloading conditions.

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Stacks Of Spring Washers Power The Drawbar On This CNC Mill Conversion

January 11, 2020 by 25 Comments

With Tormach and Haas capturing a lot of the entry-level professional market for CNC machines, we don’t see too many CNC conversions of manual mills anymore. And so this power drawbar conversion for a Precision Matthews mill really caught our eye.

What’s that, you say? Didn’t [Physics Anonymous] already build a power drawbar for a mill? They did, and it was quite successful. But that was based on a pneumatic impact wrench, and while it worked fine on a manual mill, the same approach would be a bit slow and cumbersome on a CNC mill. For this build, they chose a completely different approach to providing the necessary upward force to draw the collet into the collet holder and clamp down on the tool: springs. Specifically, Belleville spring washers, which are shaped like shallow cups and can exert tremendous axial force over a very short distance.

[PA] calculated that they’d need to exert 2,700 pounds (12,000 Newtons) of force over a length of a couple of inches, which seems outside the Belleville washer’s specs. Luckily, the springs can be stacked, either nested together in “series” to increase the load force, or alternating in “parallel” to apply the rated force over a greater distance. To compress their stack, they used a nifty multi-stage pneumatic cylinder to squash down the springs and release the collet. They also had to come up with a mechanism to engage to machine’s spindle only when a tool change is called for. The video below details the design and shows the build; skip to 11:32 to see the drawbar in action.

We’re looking forward to the rest of [Physics Anonymous]’ conversion. They’re no strangers to modifying off-the-shelf machines to do their bidding, after all – witness their improvements to an SLA printer.

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Mechanisms: The Spring

April 13, 2018 by 64 Comments

Most people probably don’t think about springs until one kinks up or snaps, but most of the world’s springs are pretty crucial. The ones that aren’t go by the name Slinky.

We all use and encounter dozens of different types of springs every day without realizing it. Look inside the world of springs and you’ll find hundreds of variations on the theme of bounce. The principle of the spring is simple enough that it can be extended to almost any shape and size that can be imagined and machined. Because it can take so many forms, the spring as a mechanism has thousands of applications. Look under your car, take apart a retractable pen, open up a stapler, an oven door, or a safety pin, and you’ll find a spring or two. Continue reading “Mechanisms: The Spring” →