Springs, Fall 2023, Volume 62, No. 4

The International Magazine of Spring Manufacturing

Vol. 62 | No. 4 | Fall 2023

SMI Turns

30 I Springs Through the Ages 31 I An SMI History Lesson 36 I A History in Photos 40 I 90th Birthday Notes to SMI from Past Presidents 44 I 2023 SMI Scholarship Program

PO Box 5668 Elgin IL 60121 Change Service Requested

Safety & Health

Cold Stress 1

The Problem

Fast Facts

4

Cold temperatures are often associated with occupations that take employees outdoors during the winter months. In addition to the obvious outdoor cold condition jobs, many employees work indoors in refrigerated environments year round. Production facilities involving food and the distribution network required to get refrigerated food products to consumers require exposure to cold conditions. Prolonged exposure can lead to cold stress. Some employers fail to recognize and address cold stress hazards due to lack of monitoring and knowing the related signs and symptoms, which include:

MAIN FACTORS

that contribute1 to cold stress:

• Hypothermia • Frostbite • Cold water immersion • Dehydration

2

• High or cold wind • Dampness • Cold temperatures • Cold water

Solutions that Work Even the most attentive, proactive worker can’t tackle the dangers of cold stress alone. A cooperative approach is important. OSHA’s guidance for cold stress prevention lists engineering controls, training, safe work practices and personal protective equipment (PPE), such as appropriate cold weather attire, as foundational components for employers to build into their work plans. Employers should: • Provide engineering controls such as thermostats and door flaps to help control exposure • Train workers on how to help prevent and recognize cold stress illnesses and injuries, and how to apply first aid treatment • Give workers frequent breaks in warm areas • Ensure employees are dressed properly in cold temperatures • Reduce exposure time • Allow workers to interrupt work if they feel a cold condition affecting them

3

70°F Hypothermia can occur in any water temperature below this level.2

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https://ehs.princeton.edu/workplace-construction/occupational-health/heat-cold-stress/cold-stress-facts NIOSH, Cold Water Immersion, June 2018 CDC’s National Center for Health Statistics Compressed Mortality Database

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Contents 36

Features

Columns

29 SMI Turns 90

4

President’s Message

15

Be Aware

Keep Bending That Steel

Phil Sasso

30 Springs Through the Ages (1200 B.C. to 1932 A.D.) Phil Sasso

31

OSHA Compliance in the 21st Century

19

The Best Way to Heat-Treat Springs

An SMI History Lesson Phil Sasso

25

36 A History in Photos

40

Dean of Springs Technically Speaking Compression Spring Design for Cryogenic and High-Temperatures

40 90th Birthday Notes to SMI from Past Presidents

65

A Message from Gary

44 T en Students Receive $23,000 in Aid Through the 2023 SMI Scholarship Program

69

Podcast Picks

71

Book Corner

Gabriela Carrasco

46 U sing Force Measurement vs. Material Testing Jacob Morales

Looking Back and Looking Forward HBR IdeaCast with Amy Bernstein The Seven Habits of Highly Effective People

Departments 7 12 51

Global Highlights Regional Reports Flashback

53

Five Questions

54

Springmaker Spotlight

Cavemen Made Own Springs

44

Asahi-Seiki Manufacturing Co. Ltd. Early Pioneers Gary McCoy

60

Women in Springs Labor and Love Sara Scullin

62 66 73 75 76

CTE News Inside SMI New Products Advertisers’ Index Snapshot Alex Altstatt, Western Spring Mfg.

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President’s Message

Gene Huber Jr.

Keep Bending That Steel

In 1933 the stock market had finally stopped its unprecedented 4-year skid that marked the beginning of the Great Depression. FDR’s “New Deal” was just starting to take shape. Amidst this chaos, a group of people decided to start an association for springmakers. This stalwart group decided that no matter what was happening at the moment, the future of the springmaking industry remained not only positive but bright.

This group was soon joined by other courageous entrepreneurs willing to defy the odds and strike out, starting their own businesses in places like Connecticut, Illinois, California and across the nation. They did this, knowing fully the risks but still seeing the worth of the bent steel products they produced. They worked long hours running their businesses while looking to the industry leaders for guidance through the lens of the association they had created.

This association still exists. It is what we now know as the Spring Manufacturers Institute (SMI).

SMI celebrates 90 years of not only existence but excellence in providing guidance, education and camaraderie to its members. Now I have to ask: What does it take to live and thrive for 90 years? From its birth in one of the toughest periods in our country’s history, through a world war, economic rollercoasters and 14 U.S. Presidents — some famous, some infamous, (I’ll let you decide who is who.) What does it take to do this?

Three themes come to mind: 1. It takes a certain toughness and passion to believe in what you’re doing and that your industry provides products needed in the marketplace.

2. It takes a willingness to learn from your mistakes and peers we respect.

3. The flip side of a willingness to learn is the spirit of educating future industry leaders from the lessons and research of yesterday and today.

This issue of Springs magazine not only provides a history of the association but also highlights what we’re currently doing to continue this tradition.

As I look back on the long history of excellence and faithfulness of our industry predecessors, I say “well done” and “mission accomplished.”

I look to the future with the hope that we will be equally courageous, stalwart and faithful to the industry we serve.

Keep bending that steel, brothers and sisters.

SMI Executive Committee President: Gene Huber Jr., Winamac Coil Spring Vice President: Don Jacobson III, Newcomb Spring Secretary/Treasurer: David DeVoe, Plymouth Spring Past President: Bert Goering, Precision Coil Spring At-Large: Dave Deerwester, The Yost Superior Co. Executive Director: Gary McCoy, SMI SMI Board of Directors Markus Arnold, WAFIOS I Joe Devany, Betts Company I Linda Froehlich, Ace Wire Spring & Form I Adam Jacobson, FENN/Torin I Don Lyons, JonSpring I Alex Melnikow, Midstate Spring I Tony Pesaresi, Winamac Coil Spring I Keith Porter Jr., Newcomb Spring I Tim Zwit, Motion Dynamics Corporation Springs Magazine Staff Gary McCoy, Executive Director/Publisher, gary@smihq.org Phil Sasso, Managing Editor, phil.springs@sassomarketing.com Gabriela Carrasco, Associate Editor, gaby@smihq.org Lisa Plefka Haskin, Art Director, lisahaskin95@gmail.com Communications Committee Chair, Keith Porter Jr., Newcomb Spring I Reb Banas, Stanley Spring & Stamping I Hale Foote, Scandic Springs, Inc. I Patrick Gillum, Gilco Spring of Florida, Inc. I Adam Jacobson, FENN/Torin I Lucas Karabin, Acme Monaco I Gary McCoy, SMI I Phil Sasso, SMI I Michael Shapiro, Gibraltar Corporation I Bill Wynn, Gardner Spring, Inc. Advertising Sales I Japan Ken Myohdai, Sakura International Inc. Head Office: 3F,4F, ENDO Sakaisuji Bldg., 1-7-3, Bingomachi, Chuo-Ku, Osaka 541-0051, Japan Phone: 81-6-6624-3601 I Fax: 81-6-6624-3602 Tokyo Global Office: 5F Kamei No. 2 Bldg., 2-17-13, Kiba, Koto-Ku, Tokyo, 135-0042, Japan Phone: 81-3-5646-1160 I Fax: 81-3-5646-1161 E-mail: info@sakurain.co.jp Advertising Sales I Taiwan Charlie Yu, Worldwide Services Co. Ltd. 11F-B, No 540, Sec. 1, Wen Hsin Rd. Taichung, 408 Taiwan Phone: +886-4-2325-1784 I Fax: +886-4-2325-2967 E-mail: marketing@acw.com.tw Springs (ISSN 0584-9667) is published quarterly by SMI Business Corp., a subsidiary of the Spring Manufacturers Institute: PO Box 5668, Elgin IL 60121 Phone: 847-450-6848; Web site www.smihq.org.

Address all correspondence and editorial materials to this address.

The editors and publishers of Springs disclaim all warranties, express or implied, with respect to advertising and editorial content, and with respect to all manufacturing errors, defects or omissions made in connection with advertising or editorial material submitted for publication.

The editors and publishers of Springs disclaim all liability for special or consequential damages resulting from errors, defects or omissions in the manufacturing of this publication, any submission of advertising, editorial or other material for publication in Springs shall constitute an agreement with and acceptance of such limited liability.

The editors and publishers of Springs assume no responsibility for the opinions or facts in signed articles, except to the extent of expressing the view, by the fact of publication, that the subject treated is one which merits attention.

Do not reproduce without written permission.

Cover designed by Lisa Plefka Haskin utilizing Shutterstock imagery.

God Bless and Have a Crazy Good Day! Gene Huber

Please archive or recycle this magazine.

Join us on social media!

Update Your Records Please be sure to update your mail and phone records with SMI’s new address and phone numbers.

Spring Manufacturers Institute PO Box 5668 Elgin IL 60121

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Fall 2023 I Springs

Main phone z 847-450-6848 Gary McCoy z 847-450-6240 Gaby Carrasco z 847-857-6432

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Global Highlights NORTH AMERICA FENN, LLC held its inaugural charity golf tournament on May 18, 2023, bringing together vendors and customers to support a local cause.

The tournament’s goal is to raise funds for charity each year, starting with The Hundred Club of Connecticut, which assists the families of fallen police officers, firefighters and correction officers.

The tournament occurred at the Robert Trent Jones Course at Lyman Orchards Golf Club in Middlefield, Connecticut. Eighty golfers participated under clear blue skies, enjoying ideal weather conditions.

The foursome from Reed & Stefanow Machine Tool secured 1st place with a score of 62, followed by FENN’s foursome in 2nd place with 63 strokes and Ulbrich Stainless Steel and Special Metals foursome in 3rd place with 64 strokes.

Aside from the main tournament, participants engaged in various competitions. Randy Roberge from Airline Hydraulics won the putting contest and closest to the pin. Justin Keough from Image360 claimed the longest drive prize, while the hole-in-one contest’s vacation prize went unclaimed.

The successful charity golf tournament marked a meaningful day of fun and support, with $15,000 raised for The Hundred Club of Connecticut.

The winning team, Reed & Stefanow Machine Tool Co. Inc., are pictured (l-to-r): Randy Roberge, Mark Evans, Joe Reed, and Chris Lombardo.

Sponsors of First FENN Charity Golf Tournament.

Pictured (l-to-r): Dale Hourigan Major, CSP, Ret., managing director for The Hundred Club of CT; Craig Watterson, sales manager; Annelise Mackiewicz, marketing & sales coordinator; Ryan Cutter, president (all of FENN).

Springs I Fall 2023

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Global Highlights After 53 years with the Bristol, Connecticut-based Fourslide Spring and Stamping, Judy Schmidt has retired as the company’s chief financial

Pictured (l-to-r); Laurie Funk and Judy Schmidt.

officer/office manager.

Schmidt started with the company in 1970 in a part-time job-share arrangement with her mother doing accounts payable, accounts receivable, and general office work. Schmidt plans to spend her retirement gardening, shopping, visiting her Rhode Island beach home, and spending time with her husband, daughter, and three grandchildren.

Schmidt is delighted to see a third-generation of the Funk family working at Fourslide. “She has long pledged not to retire until another family member was ready to take over for her, and she got her wish,” said Fourslide Spring and Stamping president Bryan Funk.

Funk’s wife, Laurie Funk, is the company’s new office manager. She spent 30 years as a paralegal and also did some bookkeeping work on the side.

Laurie jokes that she “had to come to work at Fourslide to spend more time with her husband.” She and Bryan have three children.

Hardware Products has merged with its sister division, Colonial Spring, to create New England Spring. The former Hardware Products in Chelsea, Massachusetts, has relocated its operations to Bristol, Connecticut.

With the two divisions now united under one roof, New England Spring seeks to provide enhanced customer service along with future growth and innovation.

This strategic move aims to optimize customer service by consolidating both divisions into one state-of-the-art facility. The streamlined processes and expanded capabilities will enable New England Spring to better serve customers.

The new shared location holds ISO 9001 and AS 9100 quality system certifications. This ensures all products will now meet these stringent standards. The certifications open numerous new opportunities for the company.

For more than 75 years, Colonial Spring and Hardware Products have provided materials to customers in aerospace, defense, general industrial, medical, and automotive markets.

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Fall 2023 I Springs

Stanley Spring and Stamping, a Chicago-based supplier of custom metal parts, wireforms and springs, has acquired Kehr-Buffalo Wire Frame (KBWF) of Buffalo, New York.

KBWF, an established springs and wire parts manufacturer, has been a family-owned business for nearly 70 years. Initially known as the “original” Rogers Industrial Springs, it was founded by James Rogers, Sr., in 1953. In the 1970s, James Rogers, Jr., and his wife Florence merged the company with Buffalo Wire Frame, giving rise to the new entity, Kehr-Buffalo Wire Frame. The third generation of ownership, led by brothers George and Jim Rogers, III, recently sought a strategic buyer for the company, as they planned to retire, and their next generation was uninterested in succession. The brothers will assist in transitioning their knowledge and customer relationships to Stanley Spring.

Reb Banas, president of Stanley Spring, expressed enthusiasm about the acquisition, stating that KBWF’s more than 70 years of experience and family-oriented approach align well with his company’s values.

The move will enhance Stanley Spring’s wireforming and spring coiling capabilities. The transition is expected to be smooth for existing KBWF customers, with products now delivered from Stanley Spring’s 85,000 sq. ft. Chicago facility.

Rotor Clip has launched a new website (rotorclip.com), catering to engineers, buyers and distribution partners seeking top-quality retaining rings, wave springs and hose clamps.

The user-friendly interface, exceptional customer service, and product range are designed to make the site more useful for engineering professionals and procurement specialists.

Key features of the new website include improved search functionality, easy navigation of over 20,000 part numbers, cross-referencing industry part numbers, CAD functionality for easy integration into major CAD systems, a user-friendly interface, and customization capabilities to cater to specific engineering projects.

Rotor Clip, based in Somerset, New Jersey, has more than 65 years of experience serving the diverse needs of the global manufacturing community.

Leaders In Double Disc Technology

Jack and Jeff Shoemaker, second and third generations continuing the tradition at Anchor Abrasives.

Certified to ISO 9001 since 1994.

Betts Spring Manufacturing, a division of Betts Company, has acquired Sway-A-Way Inc., a manufacturer of off-road, street, truck and circle track suspension and driveline components.

“After more than 40 years in the sway bar business, I have decided to sell the sway bar part of our business to Betts Spring,” said Brian Skipper, president and CEO of Sway-A-Way. “They have greater resources that can expand the product line, and I cannot think of a better company to take over what we have already accomplished.”

The transition was scheduled to start late April to early May 2023.

Rotor Clip has been awarded the 2022 General Motors Supplier Quality Excellence Award (SQEA).

The GM SQEA recognizes suppliers showcasing exceptional performance and rigorous adherence to quality standards throughout the year.

“Our unwavering commitment to crafting the finest rings, springs and clamps is underscored by the 2022 GM Supplier Quality Excellence Award,” said Bruce Rudin, Rotor Clip quality assurance manager. “This recognition highlights our team’s devotion to upholding impeccable quality standards across all facets of our operations.”

This achievement makes Rotor Clip one of GM’s premier supplier manufacturing sites, showcasing its dedication to delivering ‘quality at volume’ to GM manufacturing plants, said the company.

This award acknowledges a collaborative effort and strong partnership between Rotor Clip and GM. Gibbs Interwire recently welcomed Phill Cavender as vice president and general manager. Phill brings more than 30 years of metals experience to Gibbs Interwire.

He has a proven track record of achieving profitable commercial growth and Phill Cavender operational excellence through empowering and supporting his teams.

“Gibbs Interwire has a strong foundation rooted in core values,” said Cavender. “I am very fortunate to join a highly successful team and company.”

At Anchor Abrasives we specialize in the design and manufacture of resin, epoxy and oxychloride bonded nut inserted discs and cylinders...plus centerless and rollwheels.

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Springs I Fall 2023

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Global Highlights

INTERNATIONAL Alloy Wire International (AWI), a wire manufacturer, recently completed

AWI Testing: Josh Handley (Front) with Kevin Guest

a management buyout (MBO), making all employees shareholders.

Based in the U.K., the company was acquired by directors Tom Mander, Andrew Du Plessis and Adam Shaw in January. AWI extended its employee ownership program to include all 33 staff members, a commitment dating back to 1999 when founder Bill Graham introduced share ownership to involve and reward employees in the company’s growth.

AWI’s “people first” approach has resulted in significant sales growth, from $1.2 million in 2000 to $16.3 million in 2022, projected to reach nearly $22.9 million this year.

Managing Director Tom Mander emphasized the importance of employee ownership in fostering commitment and pride among the staff. The MBO allowed for the inclusion of new employees, ensuring all 33 team members could benefit from the plan, creating a close-knit atmosphere offering profit sharing, dividends and Bupa UK health benefits.

Established in 1946, Alloy Wire International specializes in manufacturing round, flat, and profile wire, utilizing over 60 Exotic alloys, serving 15 market sectors. Despite supply chain disruptions, AWI maintains its commitment to delivering materials within four weeks of order placement. The company continues to invest in assets and plans to acquire new machines to meet growing demand.

Employee ownership has proven successful, enhancing staff retention, loyalty and attracting talent to support AWI’s global expansion across 70 countries.

AWI Manufacturing Staff: Pictured (l-to-r): Stuart Hardwick and Daniel Holyhead.

The Japan Society of Spring Engineers (JSSE) held its semiannual lecture meeting, including a poster session and annual general meeting at Meiji University in Tokyo on June 7, 2023.

During the meeting, eight general lectures, one report on Committee for Selecting Spring Technological Heritage and one special topic lecture were presented to 100 attendees in a hall on the Tokyo Surugadai Campus of the Meiji University.

The opening speech was given by Kei Watanabe, a Mr. Genya Nakamura vice chairperson of JSSE and an operating officer of Chuo Spring Co., Ltd. The special topic lecture on carbon neutrality initiatives at Honda was led by Kenichi Kawasaki of the Material Research Center, Regenerative Material Research Division at Honda R&D Co., Ltd. Six technical posters were displayed in the hall. Representatives gave a brief explanation of each poster, followed by a question-and-answer session.

The top two posters were selected by participant votes. The first place poster was “Rotating Bending Fatigue Strength of Additive Manufactured Maraging Steel in Very High Cycle Fatigue Regime” by Genya Nakamura of Yokohama National University, et al. Second place went to “Fatigue Properties of TiNi Shape Memory Alloy with Passive Layer,” by Hiwa Hashimoto of Aichi Institute of Technology, et al.

10 Fall 2023 I Springs

With more than 2,000 exhibitors from 65 countries, wire and Tube 2024 will take place at the fairgrounds in Düsseldorf, Germany from April 15–19, 2024.

Covering more than 1,076,391 square feet of exhibit space, wire and Tube are expected to attract trade visitors from across the globe.

“The Düsseldorf trade fair venue is the absolute front-place for the wire and Tube sectors when it comes to presenting innovations from the relevant industries to a broad, international audience,” said Daniel Ryfisch, director of wire/ Tube & Flow Technologies at Messe Düsseldorf.

The trade fairs prioritize topics such as stainless steel, hydrogen, plastic tubes, cutting and slitting technologies, e-mobility, fastening and joining technologies, spring manufacturing technology, and glass fiber technologies. Key industries covered include chemical, oil and gas, automotive, construction, and telecommunications. wire 2024 will occupy exhibition halls 9 to 17, specifically focusing on various technologies in separate halls. Special forums, congresses, and tours will complement the events.

For more information on visiting or exhibiting at wire and Tube 2024, contact Messe Düsseldorf North America at info@mdna.com. z

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Regional Reports CASMI REPORT CASMI Hosts Golf Event at Cog Hill The CASMI 2023 golf outing at Cog Hill Golf & Country Club in Lemont, Illinois on June 15 was a tremendous success. It was 85 degrees and sunny as CASMI members and SpringWorld exhibitors participated in the 18-hole best-ball tournament. The event included lunch for golfers, and the tournament was followed by a reception, dinner and awards presentation.

Prizes were presented for the first and second-place teams in two divisions (four total) along with closest to the pin, longest putt and longest drive.

In addition, there was a raffle for three wine and beer gift baskets.

The CASMI golf outing supported the American Cancer Society, a nationwide nonprofit organization that raises money and awareness for cancer research. Participants contributed over $600 for the day to support this worthwhile cause.

CASMI’s 2024 Annual Golf Outing will be held Thursday, June 20, returning to Cog Hill Golf & Country Club.

Golfers enjoyed beauiful weather for the CASMI 2023 golf outing.

CASMI members enjoyed the 18-hole best-ball tournament.

CASMI golf tournament chairman, Larry Lieberum of ISW, greets golfers to kickoff the 2023 outing.

CASMI Scholarship Program 2023 Congratulations to our 2023 winners of the CASMI Scholarship program! Our organization once again provided over $30,000 in scholarship funds to students of CASMI members. Winners will be announced on the CASMI website (casmi-springworld.org).

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Fall 2023 I Springs

Upcoming CASMI Events CASMI has the following events scheduled for the remainder of 2023. Details will be at casmi-springworld.org before each event.

Oct. 19 SpringWorld Kickoff Meeting Cooper’s Hawk, Orland Park, Illinois Nov. 16 CASMI Meeting White Eagle Golf Club, Naperville, Illinois Dec. 7 Annual Holiday Party Cooper’s Hawk, Arlington Heights, Illinois

NESMA REPORT

By Lucas Karabin, Acme Manaco, NESMA President Now midway through 2023, NESMA is grateful for the support from our members and sponsors at our events. We look forward to an exciting second half of 2023.

In recent months NESMA has hosted events, awarded scholarships and forged new paths with local schools and government through our voting role on the “Connecticut Manufacturers Collaborative” team. Updates on the CMC can be found at nesma-usa.com.

Our May events included “Springy and Stretchy: New Materials for the Next Generations of Springs and Stampings” a presentation by Herbert Rainer, Ph.D., Materials Scientist at the University of Connecticut (UConn). The presentation guided participants through formulas and examples of new materials that challenge the status quo of materials known to exert energy. As pointed out

by Dr. Rainer, if it’s produced by man and has movement, some type of spring is required.

Our Vanguard group had a successful showing for their event at the Hartford Yard Goats baseball. A sold-out evening on May 17 included NESMA members and their families. Key sponsors included Gibbs Interwire, Radcliff Wire, and Connecticut Spring and Stamping. A great video of the event can be found on our LinkedIn page.

In June, NESMA’s scholarship committee awarded scholarships to two bright young women, Emily Seeds (St. Joseph’s College Junior) and Julian Rasten (Southington High School graduating senior), each receiving $2,500. Charlie Radcliff and the scholarship committee with the assistance of the Main Street Foundation in Bristol were presented with many excellent applicants.

Parents of current college students or graduating 2024 seniors, please encourage your sons or daughters to apply.

NESMA’s board was pleased to appoint David Devoe, CEO/President of Plymouth Spring, division of Lesjofors, as vice president of NESMA. Dave has been a member of the NESMA board for five years and currently leads our board and membership development role. Dave is also a board member and very active contributor to SMI. His support and effort on behalf of NESMA membership have been excellent.

NESMA has a new exclusive member for the insurance category, Sinclair Risk and Financial Management, which brings a team with vast experience in insurance risk assessment led by owner David Sinclair, son-in-law and company president Matt Bauer, Ribbon-cutting ceremony and employee luncheon at vice president of human Connecticut Spring and Stamping to celebrate the company’s resources Michael 50,000 sq. ft. expansion.

Goodrich, and sales Joe Pinto. Located in Wallingford, Sinclair was ranked as a “Best Places to Work” by Hearst Media in 2022.

We look forward to their professional feedback in meeting the needs of our membership.

NESMA congratulates Connecticut Spring and Stamping on the completion of their plant expansion. On June 29 a formal ribbon cutting was held with an employee luncheon. The expansion of the Farmington facility will increase their NESMA Vanguard members floor space by 50,000 sq. ft. It also features high enjoyed a night at the Hartford Yard Goats game ceilings and reinforced floors to meet the stanin May. dards for its modern press equipment. Speakers included Lieutenant Governor Susan Bysiewicz, Connecticut Chief Manufacturing Officer Paul Lavoie, CBIA President and CEO Chris Dipentima, and Connecticut Spring and Stamping President Steve Dicke. z

Upcoming NESMA Events NESMA has the following events scheduled for the remainder of 2023.

Details will be at NESMA-usa.com before each event.

Oct. 4 Presentation by Solar Atmospheres Fundamentals of Vacuum Heat Treating Taino Smokehouse Prime, Meriden, Connecticut Dec. 7 Annual Holiday Party & Awards Ceremony Location TBD

Springs I Fall 2023

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Be Aware

Laura Helmrich-Rhodes, CSP, Ed.D.

OSHA Compliance in the 21st Century As we celebrate SMI’s 90th anniversary , I want to update you on current Occupational Safety and Health Administration (OSHA) compliance trends and share some history of a few regulations to which employers must comply.

The OSHA Act, passed on Dec. 24, 1970, aimed to protect workers from poor working conditions. The Act created the National Institute of Occupational Safety and Health (NIOSH), which still is dedicated to research, education and training. It created a means to promote safety and health regulations and set up a means to enforce those regulations. Before OSHA, there were many strikes over working conditions, and unions mobilized workers to push for federal legislation (Rosner and Markowitz),. The Mine Safety and Health Act (1969) preceded OSHA due, in part, to highly publicized mine accidents and the strength of unionized workers.

The Construction Safety Act (1969) and some water quality standards (1948) were already on the books when OSHA passed, but these were not the first safety regulations in the U.S. In 1877, Massachusetts passed the nation’s first factory inspection law. It required guarding of belts, shafts and gears, protection on elevators and adequate fire exits. Its passage prompted a flurry of state factory acts. By 1890, nine states provided for factory inspectors, 13 required machine guarding, and 21 made limited provisions for health hazards.

(See Passage was Perilous.)

Other influences on safety standards brought working conditions and chemical concerns to the public, including the Pittsburgh Survey (1907-1908), which included a “death calendar” showing that a worker died every day in Allegheny County. This led to the creation of organizations such as the National Safety Council (1913), which continues to provide support, such as training materials for worker safety and health, and a significant focus on reducing roadway accidents.

Upton Sinclair’s investigative journalism, The Jungle, helped to move forward the Pure Food and Drug Act in 1906. Rachel Carson’s Silent Spring (1962) highlighted the use and environmental impact of DDT, a chemical pesticide.

Highly publicized American tragedies like the Triangle Shirtwaist Factory Fire (1911) also created fire and emergency evacuation laws.

The modernization of America, moving from agriculture to a more industrialized, mechanized factory system, increased the dangers workers faced. Social reforms such as the creation of the U.S. Department of Labor (1913) included forward -thinking safeguards such as the protection of female and child workers and the passage of the of the first, legal workers’ compensation act (Wisconsin 1915). After a whirlwind of employee walkouts, crime and even gunfire, labor was organizing into unions to address wages and conditions.

Fast forward to my nearly forty-year career, the last seven with SMI have spanned several presidential administrations which have directly impacted the role and strength of labor laws. I’ve been blessed to see the further modernization of factories, health care, construction trades, gas and oil extraction and the increasing role of digital technology.

Over that same time, court decisions and worldwide disasters have influenced workplace best practices and OSHA regulations. Just to name a few that are memorable to me and had a direct impact on EHS: Bhopal, India (1984), Chernobyl (1986), Space Shuttle Challenger (1986), Phillips 66 chemical explosion (1989), Exxon Valdez (1989), Imperial Foods chicken processing fire in Hamlet, North Carolina (1991), BP refinery explosion, Texas City (2005), Hurricane Katrina (2005), Imperial Sugar dust explosion in Port Wentworth, Georgia (2008), Deep Water Horizon oil rig explosion (2010), Upper Big Branch Mine Disaster (2010), Kleen Energy CT Power plant explosion (2010), Fukushima (2011), Hurricane Sandy (2012), West Fertilizer explosion (2013), Hurricane Matthew (2016) and of course, COVID-19 (2020). Each of these heightened awareness, and some even can be linked to specific OSHA regulations.

The Modern Work World and OSHA Most Frequently Cited Standards Many of the issues unions fought for at their inception are now legislated. Wage and hour laws at both state and federal levels, along with more strict safety and health laws, have been promulgated, especially for those doing highly hazardous work such as logging, meatpacking, electrical, confined space, mining, hazardous chemicals and working at heights — not to mention, finally, regulations that improve conditions for Americans’

Springs I Fall 2023

15

Be Aware with Disabilities and protection of whistleblowers, freeing them from retaliation. There is still room for improvement, particularly in adopting modern chemical exposure limits. Most employers I have met sincerely care about their employees and their obligations to abide by the laws set forth to create the best wages, hours and conditions.

The top most frequently cited standards in the spring and wireforming industries continue to be pretty consistent: protection from chemical exposure (Hazard Communication), contact with electricity (suitable wiring and lock out/tagout), proper OSHA recordkeeping/reporting and failure to protect employees from being caught in machinery (point of operation and mechanical transmission). We have come a long way in giving workers a voice and reducing the fear of retaliation, but there is still work to do to prevent catastrophic disasters and personal injury. In 2021, 5,190 workers died, and an estimated 2.6 million were injured or became ill. (U.S. Department of Labor Assistant Secretary for OSHA Doug Parker, Address, July 18, 2023) In January 2015, OSHA began to require all covered employers to self-report any amputations, loss of an eye, or overnight stay in a hospital of one employee. Accumulating this data has improved our understanding of accident causation and frequency. The U.S. Bureau of Labor Statistics reported in 2020, using 2018 data that “machinery was involved in 58% of work-related amputations.”

The median days away from work to recover from a workplace amputation is 31 days. (Economics Daily) OSHA continues to operate under a national emphasis program (NEP) to prevent amputations.

The manufacturers of spring, wire and metal forming machinery need to be aware of this data and provide customers (employers) with modern, viable options for prevention.

July 2023 OSHA Announcement Among the top 10 most frequently cited regulations for the spring and wireforming industry is recordkeeping, and, as fate would have it, OSHA just announced the expansion of recordkeeping obligations. Most of our readers (10 or more employees over a calendar year) are already obligated to keep OSHA records of serious work-related injuries and illnesses (Form 300 and 301) as well as a report via online or phone death or severe injuries (see definitions of severe injuries above). This recent announcement impacts some of our readers (those with more than 100 employees in a calendar year).

The original OSHA injury and illness recordkeeping and reporting rule (July 1971) required all employers covered by the OSH Act to maintain injury and illness records. In October 1972, an exemption from most of the recordkeeping requirements was put in place for employers with seven or fewer employees. In 1977, OSHA amended the rule to exempt from recordkeeping employers with 10 or fewer employees (over the calendar year), and that exemption has continued in effect to this day (See Preamble Discussion) On July 17, 2023, OSHA published a news release announcing rules expanding electronic records submission requirements for injury and illness data provided by establishments with 100 or more employees in specific high-hazard industries

Number of nonfatal workplace amputations involving days away from work by selected types of machinery as source of injury, all ownerships, 2018 2,000

1,660

1,500

640

500

610 470 200

0 Metal, woodworking and special material machinery

16 Fall 2023 I Springs

Special process machinery

All other machinery

Material personnel handling machinery

Construction, logging and mining machinery

Source: U.S. Bureau of Labor Statistics.

1,000

based on the NAICS code. This new rule takes effect on Jan. 1, 2024 (OSHA News Release).

It was already established that employers with 20 employees in spring and wire manufacturing had to electronically submit (not just maintain) the OSHA Form 300 — Log of Work-Related Injuries and Illnesses. Now, this is expanded to those with 100 employees to electronically submit information from Form 300 — Log of Work-Related Injuries and Illnesses and Form 301 — Injury and Illness Incident Report to OSHA once a year. To further improve data quality, establishments must include their legal company name when making electronic submissions to OSHA from their injury and illness records. Some of this information will be made public.

Readers are encouraged to do two things if they fall into this group. First, if you have not done so, create your electronic submission account immediately. Waiting until the due date will likely lead to chaos and frustration. Second go to the OSHA website link for more updated information as this rule is implemented (osha.gov/recordkeeping)

The Future Learning from our history and avoiding similar injuries and illnesses is paramount, but it would be more productive to be innovative and predictive versus reacting to catastrophes to cause change. Engaging employees for their valuable insight into quality/safe product manufacturing and accepting only safely engineered new equipment innovations is the way to avoid citations and reduce industry loss experience.

Happy birthday SMI! z

Sources and Helpful Links

How to Set Up an OSHA Tracking Application (Retrieved 7/19/2023) youtu.be/-e6i7xHuv7Y

Laura Helmrich-Rhodes, CSP, Ed.D., is the SMI's regulatory compliance consultant. She is an associate professor in the Safety Sciences Department at Indiana University of Pennsylvania, teaching graduate and undergraduate classes.

Preamble Discussion of Section 1904 Recordkeeping (Retrieved 7/18/2023) bit.ly/1904-records

Contact Rhodes at SMI: 847-450-6848 laurahrhodes@gmail.com

Chemical Safety Board: Combustible Dust Investigation (retrieved 7/15/2023) bit.ly/combust-dust Economics Daily (Retrieved 7/16/2023) bit.ly/machine-amp

Recordkeeping Fact Sheet (retrieved 7/19/2023) bit.ly/osha-fs (pdf) The Job Safety Law of 1970: Its Passage Was Perilous ( Retrieved 7/12/2023) bit.ly/jobsafety-70 OSHA List of National Emphasis Programs bit.ly/osha-nep OSHA News Release (July 17, 2023) bit.ly/osha-expand-req-2024 Q &A About Electronic Submission of OSHA Data osha.gov/injuryreporting/faqs Washington State Department of Labor and Industry: History of Process Safety bit.ly/wa-safety-train Rosner D, Markowitz G. A Short History of Occupational Safety and Health in the United States.

Am J Public Health. 2020 May;110(5):622-628 ncbi.nlm.nih.gov/pmc/articles/PMC7144431/

Percent of nonfatal workplace amputations involving days away from work by selected source of injury, all ownerships, 2018 70%

60%

58% 50%

40%

20%

15%

10%

8%

8%

7%

Containers, furniture and fixtures

Vehicles

Tool, instruments and equipment

0% Machinery

Parts and materials

5% All other sources

Source: U.S. Bureau of Labor Statistics.

30%

Springs I Fall 2023

17

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Dean of Springs

Dan Sebastian

The Best Way to Heat-Treat Springs In past articles, we have discussed the need to properly heat-treat springs to get the most efficient spring performance. We all know that heating a spring works but selecting the most efficient method of heating may be helpful to see how heating really works.

First, what is heat? Heat is a measure of energy and is the product at the molecular level.

All materials are made up of atoms or combinations of atoms called molecules. These atoms or molecules (particles) are in constant motion, and heat is the measurement of the energy from the particle's motion—generally, the faster the motion, the higher the energy (i.e., heat). In metals, the collection of particles is constantly colliding with each other. The faster they collide, the higher the temperature of the material. There are several different ways to ramp up the collision, which creates heat. Exposure to raw energy causes metal to heat up by different methods. When the energy surrounding a metal object is the same as the metal, they are at equilibrium for that time. Some of the methods used to heat springs are: • Conduction

• Convection • Resistance • Induction • Radiation They can be used alone or in combination with other methods.

Conduction

The most common method of heating metal springs, and perhaps the oldest, is conduction.

It is when you put a spring in a flame (energy source) or on a hot surface. It is time-dependent (some things can speed up the process, but they are still limited to the basic metallurgy of thermal conductivity).

Conduction occurs when an energy (hot) source is in contact with a lower-temperature body.

The higher-speed (hot) particles collide with the lower speed transmitting their energy. This continues until the speed of the particles in each body is the same. The transmission rate is time-dependent based on the material and the contact area. It can be complicated to control because of heat losses to the surrounding area.

Caution must be used as time dependence can cause localized overheating that can cause metallurgical changes.

Conductive heat transfer can be calculated by: Fourier's Law q = (k/s) A dT q = U A dT

(1)

where q = heat transfer (W, J/s, Btu/hr) k = Thermal Conductivity of material (W/m K or W/m °C, Btu/(hr°F ft2/ft)) s = material thickness (m, ft) dT =temperature differential in °F A = heat transfer area (m2, ft2) U = k/s Fig. 2. Fourier’s Law allows you to calculate the time required to reach temperature

Fig. 1. Conduction occurs when there is direct contact with the energy source.

One of the most sophisticated forms of conduction heating is the vacuum furnace. Springs are placed in an airtight furnace that is evacuated to remove all particles. The fully evacuated chamber

Springs I Fall 2023 19

Dean of Springs

Convection

faster the particle movement, mass and density of the fluid, the faster the heating, but it is again limited by the material. The process is much easier to control as fluid can be uniformly heated.

Vigorous agitation or stirring may be necessary because vapor barriers can occur, reducing the efficient transfer of energy. Water and oil are limited to the maximum temperature and require containment to control the environment.

Fluidized beds are very efficient but can be messy.

This makes air the most efficient, but at higher temperatures, the loss in density decreases its efficiency. The efficiency of the process is controlled by the design of the containment zone.

Air movement is a cost-effective method to heat by convection. Increasing air speed can speed up the process but has limitations, as the higher the temperature, the less dense it is, which means there are fewer particles to transmit the energy.

Fig. 4. Convection occurs when the fluid molecules collide with the spring

Fig. 5. Air at room temperature

Convection occurs when energy (heat) is transferred by fluid movement around a body(spring).

The fluid can be air, water, oil, liquid salt or a fluidized bed, usually consisting of air and sand. The

The flow rate in an oven can be measured as the number of air changes per minute. The data above shows that density reduction can significantly reduce the effectiveness at elevated temperatures.

Fig. 3. Vacuum furnace is a pure conduction method

is then heated, and the hot chamber conducts heat to the parts inside. The equipment is costly and difficult to maintain, so it is used on metals that can be contaminated or changed metallurgically by exposure to any form of atmosphere.

Fig. 6. Air at 800°F

Air density and specific weight at atmospheric pressure 0.14

4.00

Density

0.12

Specific weight

3.00

0.10

2.50

0.08

2.00

0.06

1.50

0.04

1.00

0.02 0.00

0.50 -150

0

150

300

450

600

750

Temperatutre [°F] Fig. 7. Graph of air vs. temperature

20 Fall 2023 I Springs

900

1050

1200

1350

1500

Specific weight [lbf /ft3]

Density [sl/ft3 * 10-3]

3.50

Resistance

Induction

Fig. 8. Resistance heating occurs when electric current is passed through a spring

Resistance heating occurs when electricity is passed through a metal. Some metals conduct electricity more efficiently than others. As the voltage and amperage increase, the resistance increases, which increases the temperature. It is very controllable, but like conduction, it takes time, starting at the ends and moving to the middle. There are inherent dangers when using resistance as a method of heating. One of the most significant is the danger of arcing—the danger of arcing increases with voltage.

Arcing is like lightning when a high potential charge reaches a lower potential area. The difference is so great that it ‘jumps’ through the air, which is not a good conductor. In many cases, the temperature of the arc can be intense enough to cause micromelting of the material. This can be seen in the form of a pit. This can cause a phase transformation in steels with subsequent rapid cooling that can produce untempered martensite.

Raw martensite is so hard that it can cause crack formation. The crack can act as an infinitely sharp notch starting crack propagation.

There are several cases on record of arcing pits causing premature failures.

Early in my career, I was called in to investigate a series of premature failures. The customer was perplexed because to assure the reliability of the parts, they had required magnafluxing to assume quality. After countless hours of investigation, we discovered that an arc would occasionally occur in the dead coil area during charging. However, sometimes it would jump to the active area creating the initiation point for cracks to grow. We later found the same failure mode on springs heated with resistance.

Resistance heating is very energy efficient as most energy is used to heat the part.

Fig. 9. Induction heating occurs when a spring is in the middle of intense magnetic waves

Induction heating involves passing a current through an induction coil, creating an electromagnetic field within the coil, which will heat steel, copper and other metals. Unlike exciting molecules with a temperature differential or an electric current, the magnetic field causes violent molecular motion, creating heat.

The process requires sophisticated controls and symmetric parts. The process is often used where the material is undergoing a phase transformation, like in hardening or annealing. Special consideration must be taken because of the volumetric changes in the material. Like electrical resistance heating, the process can be very efficient as the energy is mainly used to heat the part.

Radiation

Fig. 10. Radiation occurs when the spring is exposed to infrared radiation

Radiation can come in different forms, like infrared or nuclear. Nuclear radiation can only create heat in certain metals under specific conditions.

Springs I Fall 2023

21

Dean of Springs In commonly used materials, it does not create heat but can cause embrittlement. Infrared radiation, like the sun's heat, can be used to heat metals, even springs. It can be efficient but requires sophisticated controls.

Summary of Heating Methods Each of the different methods for heating springs can be effective, and combined with multiple methods can increase cost efficiency. The heating of springs is absolutely needed for springs to perform their mission of storing and delivering energy to operate mechanical components.

The cost of delivering that energy can vary significantly. Electricity is clean and convenient but can be costly (depending on the production method, it may not be as clean as it would appear).

Natural gas is abundant and restively clean; its cost-effectiveness may be subject to governmental control because of CO2 emissions. The cost of maintaining either system can vary. Historically natural gas has been less costly to maintain, but recent advances in electric equipment designs have closed the gap.

Combined Methods The most commonly used methods are a combination of conduction and convection ovens. We see them everywhere, from kitchens to commercial heat treaters. Ovens come in many forms. The three most common types are box, conveyor or shaker hearth ovens. Each has its advantages in both cost and efficiency depending on the type of process required for spring performance or the customer’s specifications.

Box Ovens

Choosing the Best Method Choosing the best method or methods to effectively heat-treat a spring is dependent upon many things, but first you need to determine if you are relieving stress or trying to change the metallurgical structure.

Changing the metallurgical structure can involve phase changes or precipitation strengthening. Then you must consider the following: 1. How many parts do you have to process?

2. What is the available equipment, or what do you have to purchase or use an outside service?

3. Is time critical to the heat-treating process?

4. Does the heat treatment require special handling, such as a protective atmosphere or cleaning?

After answering all those questions, you can select which method or methods you should use.

Resistance or induction heating usually requires tooling that is part specific. This means that they are typically used for higher volumes.

A potential advantage of these methods where metallurgical changes are required is the inherent speed may eliminate the need for protective atmospheres. In medium and high carbon steels, the normal brief time at temperature can also minimize the possibility of quench cracking.

22 Fall 2023 I Springs

Fig. 11. A typical box oven

Box ovens come in varied sizes and shapes. In most cases, their dominant form of heating is conduction supplemented by convection from the fluid or fluids in the form of a gas surrounding the mass of parts. As the temperature increases, molecules in the gaseous fluid speed up, impacting the springs, creating heat.

One problem with using gaseous particles at elevated temperatures is their density decreases, resulting in fewer particles impacting the non-contact areas. Frequently these ovens have fans to direct the fast-moving particles to speed up the natural convection currents. They may be the ultimate set-and-forget process. By their nature, they are slow and time is money. The density of the load can affect the time required for the entire load to reach the desired temperature.

In today’s world, the moderate cost of suffocated instrumentation makes it easy to monitor the effective temperature of the oven load. I have found placing the thermal couple in the load's center useful. The best quality control practices would dictate measurements to confirm temperature uniformity throughout the load.

A subsector of box ovens is vacuumed ovens or furnaces. The chamber is sealed, and a vacuum is drawn that eliminates any atmosphere. Vacuum ovens are used in special applications where the material must not be exposed to any material that could contaminate the parts in the chamber.

Continuous Belt or Shaker Hearth Ovens These ovens allow the parts to move continuously, which means they are exposed to a heat source as it moves through the oven. The parts are usually less densely packed and may be exposed to the heating source.

More parts in contact with the belt or hearth increase the surface contact for conduction. In round wire and cylindrical springs, the contact area can be small.

Fans are usually used to expose the parts to more fluid (usually air). The problem with moving hot air is the higher the temperature, the less dense the air. The fan design is critical to moving as many particles as possible to increase the convection currents. Belts move the parts more uniformly than shaker hearths but require more energy to reheat the belt continuously.

A significant advantage of continuous flow ovens is that the closer they are to forming, the more you can use the latent heat of forming to decrease the energy required to bring the part to the desired temperature.

Depending on the severity of the forming, the parts can be hundreds of degrees. Another option to increase the efficiency of the continuous flow oven. This can be accomplished by reducing the

Fig. 12. Continuous belt oven

distance from forming to entry into the heating chamber and by using infrared lamps over the unseated portion of the belt or hearth.

Conclusion In many ways, treating a spring post-forming is the most important operation you will do to ensure the part performs its design function and results in the customer’s parts being world-class.

In designing the best heat treatment method, you should work closely with your equipment supplier to ensure that you incorporate the quality principles of Deming and Juan that eliminate as many of the operations as possible to limit the sources of variations. z

Fig. 13. Shaker Hearth Oven

Dan Sebastian is a former SMI president.

He holds a degree in metallurgical engineering from Lehigh University, and his industry career spans more than four decades in various technical and management roles.

Contact Sebastian at SMI: 847-450-6848.

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Technically Speaking

C. Richard (Rick) Gordon

Compression Spring Design for Cryogenic and High-Temperatures Springs used in cryogenic and high-temperature applications is outside the normal range of products that many spring manufacturers currently produce. However, such springs may present opportunities for future business.

How does one design and test the load and deflection specification limits for springs operating at cryogenic and high temperatures?

For this article, I will focus on one spring type, helical cylindrical compression springs made from round wire.

Material Selection In the SMI 7-step spring design process shown in Figure 1, step 3 is material selection. As we teach in the SMI Spring Design courses, spring materials selection depends on engineering and commercial factors (see Figure 2).

Engineering factors include: 1. Environment: Will the spring be subjected to a corrosive environment or extreme temperatures such as cryogenic or high temperatures where relaxation can be critical?

2. Stress condition: Is it a high-stress or low-stress application?

3. Fatigue condition: Is it a static or low cycle, medium cycle, or a dynamic high cycle application?

Commercial factors include cost and availability.

For this example, I will examine one material that is suitable for low-temperature applications (temperatures down to -423°F (-253°C)) and high-temperature applications (temperatures up to 1100°F (593°C)). A suitable choice is Inconel® 718. Inconel® 718 (UNS N07718) is an age hardenable, high-strength, corrosion-resistant nickel– chromium–molybdenum–niobium superalloy.

Spring Rate First, the influence of material properties at different temperatures on spring rate as a design parameter will be presented.

For compression springs, the equation to calculate the spring rate (k) is: k=

Gd4 8NaD3

Where: G = modulus of rigidity, shear or torsion modulus d = wire diameter Na = number of active coils D = mean spring diameter

Step 3

For compression springs, the material property of interest is the modulus of rigidity, [G]. The modulus of rigidity [G], Young’s modulus [E] and minimum tensile strength are a function of temperature, as shown in Table on page 26 for Inconel® 718.* In cases where only Young’s modulus has been measured at certain temperatures, the modulus of rigidity can be calculated.

The following equation defines the relationship between Young’s modulus [E] (aka modulus of elasticity, elastic modulus or bending modulus) and the modulus of rigidity [G] (aka shear modulus or torsion modulus) for elastic isotropic materials:

Define the Design Problem Select Spring Configuration Select Material (family) Select Stress Level Design to Optimize

G=

Check Design Specify

E 2(1+ν)

Where: G = modulus of rigidity E = Young’s modulus ν = Poisson’s ratio

Fig. 1. SMI 7-step Spring Design Process.

Springs I Fall 2023 25

Technically Speaking Design Example

Material Selection

(°F)

(°C)

Young’s Modulus [E] (x 106 psi)

-300

-184

31.3

12.5

237

An Inconel® 718 compression spring of 0.375 inches outside diameter with closed and ground ends is required for a valve.

For this example, 0.053 in. diameter wire will be used. The ends will be closed and ground.

The spring will be designed to operate in three temperature regimes: -300°F, ambient (70 – 80°F), and 1100°F. The free length of the spring Lf is specified as 0.590 in. Load testing is specified at lengths L1 = 0.550 in. and L2 = 0.400 in.

Advanced Spring Design (ASD) software4 is our tool of choice for spring design calculations.

New materials were added to the database for the -300°F and 1100°F temperatures because of the different properties of the materials at these temperatures.

Table 2 shows spring design parameters and calculated results.

As a general guideline, strength and modulus will increase as temperatures drop below room temperature. Therefore, if specific test data at cryogenic temperatures are not available, springs for service at these temperatures may be safely designed based on room-temperature properties2.

70-80

21-27

29.0

11.2

210

Summary

1100

593

24.2

9.5

167

The impact of the change in temperature on material properties and the calculated spring rate and design parameters have been shown for super alloy Inconel® 718, a most versatile material for special spring applications. z

Selection of spring materials depends on: Environment: corrosive, low-temperature, high-temperature (Relaxation) Stress conditions: High vs Low – stress

Engineering Factors

Fatigue Conditions:

Low, medium, high – cycle

Static or dynamic fatigue

Cost

Commercial Factors

Availability Fig. 2. Spring Material Selection Criteria.

Table 1: M odulus and Minimum Tensile Strength Values for Inconel® 718 at Select Temperatures2,3 Temperature

Modulus of Rigidity [G] (x 106 psi)

Minimum Tensile Strength (ksi)

Table 2: S pring Design parameters and Calculated Results Material

Inconel® 718

Inconel® 718

Inconel® 718

End Type

Closed/Ground

Closed/Ground

Closed/Ground

-300 °F

Ambient (70-80 °F)

1100 °F

EnvironmentTemperature

Acknowledgements The assistance of Dr. Terry Bartel, Charter Steel, retired and Todd Piefer, Universal Technical Systems, in the preparation of this article is acknowledged and appreciated.

Condition

Preset

Preset

Preset

Tolerance

Precision

Precision

Precision

References

Modulus of Rigidity [G] (psi)

12500000

11200000

9500000

Wire Diameter [d] (in.)

0.053

0.053

0.053

Spring OD (in.)

0.375

0.375

0.375

1. Encyclopedia of Spring Design, Compression, Extension, Garter and Torsion Springs, SMI 2000, p. s5.

Spring Mean Diameter [D] (in.)

0.322

0.322

0.322

Active Coils [Na]

4.6

4.6

4.6

3. T. Bartel, Private communications.

Calculated Spring Rate [k] (lbf/in.)

80.28

71.93

61.01

4. Advanced Spring Design (ASD) software, www.smihq.org, www.uts.com/Products/Asd

Cycle Load 1 [P1] (lbf)

3.211

2.877

2.44

Cycle Length 1 [L1] (in.)

0.550

0.550

0.550

Cycle Load 2 [P2] (in.)

15.253

13.667

11.592

Cycle Length 2 [L2] (in.)

0.400

0.400

0.400

Free Length [Lf] (in.)

0.590

0.590

0.590

2. Inconel® alloy 718, Special Metals Corporation, Publication No. SMC-045, Sept. 2007, www.specialmetals.com

® * INCONEL is a trademark of the Special Metals Corporation group of companies.

C. Richard (Rick) Gordon is the technical director for SMI. He is available to help SMI members and non-members with metallurgical challenges such as fatigue life, corrosion, material and process-related problems.

Contact Gordon at 574-514-9367 or c.richard.gordon@gmail.com.

26 Fall 2023 I Springs

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2024

EXPO AND SYMPOSIUM

EXPO AND SYMPOSIU

ROSEMONT, ILLINOIS • OCT 2-4

Presented by CASMI and S

Presented by CASMI and SMI

CASMI and SMI PARTNER TO HOST A JOINT EVENT SMI brings symposium to SpringWorld!

Three Days of EXPO

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Technical Theater Sessions

Same Great Networking Events

Chicago Association of Spring Manufacturers, Inc. (CASMI) and The Spring Manufacturers Institute (SMI) have partnered to combine the two organizations’ semi-annual events into one industry foremost event. The joint SpringWorld Expo and Symposium will be held October 2-4, 2024, at the Donald E. Stephens Convention Center in Rosemont, Illinois. In addition to the CASMI hosted exhibit hall, SMI will also host two mornings of business and technical content, including 24 educational sessions. Exhibit hall hours will be similar to prior years and the technical theater and receptions return!

Don’t miss this comprehensive educational and networking event to learn the latest from suppliers and educators.

Registration will open later this year!

For Exhibitor and Sponsorship information, email: info@casmi-springworld.org.

October 2-4, 2024 • Donald E. Stephens Convention Center • Rosemont, IL • casmi-springworld.org

SMI Turns

By Phil Sasso

90

Turning 90 this year is a landmark for the Spring Manufacturers Institute (SMI).

Celebrating a 90th anniversary is an amazing feat for any business, much less for a trade association laser-focused on one category. It demonstrates how a long list of leaders with vision have worked together to build lasting relationships and an infrastructure to keep SMI relevant with individuals and member companies. The spring industry also has a long, robust history of family businesses operating for generations. Many companies can trace their legacy back three or four generations. That, too, is remarkable.

In celebrating SMI’s heritage, we turn this section of the magazine into part history book, part yearbook. Our goal is to tell the backstory to put today’s SMI in context.

In “Springs Through the Ages” (page 30) and “Flashback: Cavemen Made Own Springs” (page 51) by late SMI member Harman McBride from Springs’ debut issue in 1962, we study the evolution of the unassuming spring and the resilient spring man­ ufacturing industry. Before SMI’s founding in 1933, springs and their ability to store and release energy have inspired inventions and businesses from pre-historic to the Industrial Revolution and from the space age to the digital era.

If you turn to “Springmaker Spotlight: Early Pioneers” (page 54), you’ll find SMI executive director Gary McCoy’s account of two trailblazing spring

manufacturers that predate Lincoln’s presidency.

John Evans’ Sons, Inc. and Betts Company, SMI charter members, not only survived, but they also thrived for decades.

Using a timeline of SMI’s 90 years of progress, “An SMI History Lesson” (page 31) studies key points in the association’s development. We see how it grew from a Depression-era manufacturers association to a vibrant institute focused on disseminating business and technical information and building an active network of springmakers and suppliers.

And finally, we turn an eye to the names and faces that have been part of SMI over the last nine decades.

We see historic photos of members, speakers and artifacts in our yearbook-like gallery, “SMI History in Photos” (page 36). And we close our feature section with “Birthday Notes from Past Presidents” (page 40), where former leaders share their thoughts and well wishes.

Of course, we can’t look back without taking a moment to look forward. If you are a member, we thank you for your current and future involvement.

Not a member? Please consider joining to be a part of the rich history, professional relationships and educational resources of SMI. For more information on membership, contact Gary McCoy, SMI executive director at 847-450-6240 or gary@smihq.org. z

Springs I Fall 2023 29

Springs Through the Ages (1200 B.C. to 1932 A.D.)

By Phil Sasso

Wallace Barnes, circa 1863

Edward Dunbar, circa 1850

30 Fall 2023 I Springs

Outsiders may not appreciate the backstory of mechanical springs. But the story of the not-so-simple spring and the industry it has spawned is intriguing.

The earliest known springs were used in bows. By 1200 B.C. Europe, jewelers secured brooches with helical torsion springs — basically the first safety pin. Later, ancient Greeks and Romans used primitive springs in catapults. In first-century Greece, engineer Ctesibius of Alexandria’s bronze alloy springs were reportedly used in clocks, weapons, and musical instruments.

Fast forward to The Renaissance when Leonardo DaVinci redesigned the catapult (circa 1485) using the spring-like energy stored in bent wood to power the swing arm. DaVinci had engineering ideas, including a few spring designs, only realized in his sketches and notes.

In 1676, British physicist Robert Hooke postulated Hooke’s law: “The force a spring exerts is proportional to its extension.” In 1763, the first coiled spring was patented by Richard Tredwell, a British inventor. Tredwell’s spring was used in carriage suspension to replace leaf springs.

Perhaps every springmaker knows that in 1858, Wallace Barnes and Edward Dunbar formed a business partnership to make clock springs and hoops for hoop skirts in a factory called Crinoline Hall (a “crinoline” was a hooped petticoat). They ran three eight-hour shifts a day to keep up with demand. By 1863, the hoop skirt fad was over, and the partnership dissolved. The two men separately built legendary springmaking companies eventually among the founding members of SMI. By the late 1920s and early 30s, The Great Depression had significantly impacted the spring industry, forcing layoffs, wage reductions, and slashed operating costs. However, new springmaking businesses were still formed and new technology developed.

One advancement was shot peening (bombarding a spring with “shot” to improve fatigue resistance). There are several versions of thow it orginated, but all agree that a major automaker rejected a valve spring order for rough, dull surfaces caused by sandblasting. The chief engineer ran tests and found the sandblasted springs had greater fatigue resistance. When the automaker repeated the test, the order was accepted and shot peening was born.

Another significant advancement was the development of high-strength, corrosion-resistant, heat-treated beryllium copper springs.

Unlike bronze and brass, developed centuries earlier, beryllium was first created in 1828 by a reaction of beryllium chloride with potassium. But it took about a century before the first beryllium copper conductive springs were mass-produced for telephone switchboards.

In 1930, the Spring Research Board was formed during the Depression to exchange information and cost-cutting techniques. The bureau held several meetings but quickly dissolved.

In 1932, Franklin Delano Roosevelt was elected in a landslide victory. FDR’s 1933 National Recovery Act set the stage for the next advancement in spring manufacturing history. z

An SMI History Lesson • 1933–2023

By Phil Sasso

Franklin D. Roosevelt was sworn in as U.S. president March 4, 1933, at the height of the Great Depression. On his second day in office, he closed banks for four days to end the run by depositors.

On June 16, 1933, Roosevelt enacted the National Industrial Recovery Act (NIRA), an economic stimulus law that allowed the federal government to regulate prices, wages and other business areas.

SMA is Born On August 11, 1933, a group of spring manufacturers met in Buffalo, New York, to form the Spring Manufacturers Association (SMA). SMA was created in response to FDR’s NIRA, which required the creation of industry-wide codes designed to promote recovery and prevent unfair trade practices.

SMA adopted the Code of the Finished or Component Metal Products Fabricating Industry as its basic code. This code established a minimum hourly wage of 40 cents for males and 35 cents for females and a 40-hour week.

SMA also established a committee to create a supplemental code to define fair practices in the spring industry.

Although the NIRA was considered unconstitutional in 1935, and a failure by many historians, it was responsible for the SMA’s establishment. SMA eventually became the cornerstone of the precision spring industry across North America.

Barnes Leads SMA At the center of the new SMA was spring industry pioneer Fuller F. Barnes. He served as its president from 1933 to 1941 and again from 1944 to 1946.

Under Barnes’ leadership, the SMA grew from a small group of 40 spring manufacturers to a major force in the industry. He helped establish SMA as a leading source of information and education for spring manufacturers, and he also played a key role in developing the SMA’s standards for spring design.

Barnes established SMI’s standards committee.

This committee developed a comprehensive set of spring design standards that manufacturers still use.

Barnes was voted “Honorary President for Life” in 1941.

The Wahl Factor Dr. A.M. Wahl, a career-long engineer in research and development at Westinghouse, was indisputably one of the leading figures in modern spring manufacturing history. In the late 1920s, he began to study stress and spring failure and created the “curvature-stress-correction,” also known as the “K Factor.”

In 1944, McGraw-Hill published Wahl’s landmark book “Mechanical Springs,” still considered by many the de facto standard and ultimate

“Mechanical Springs” by A.M. Wahl published

Spring Manufacturers Association founded 1933

“Spring Principles and Design” Raymond Mfg Co. (Associated Spring) 1935

1934 SMA moves office from Buffalo, NY to Bristol, CT

1937 1936

1939 1938

International Organization for Standardization (ISO) founded

Fuller F. Barnes voted “Honorary President” for life 1941 1943 1940

1942

1945 1944

1947 1946

World War II ends

World War II begins Japanese attack Pearl Harbor

Slinky invented

by Richard and Betty James

Springs I Fall 2023

31

sourcebook for springmakers. Publication of Wahl’s book set the stage for “spring science” and established the framework still primarily used today. The second edition was published in 1963

by McGraw-Hill. With McGraw-Hill’s permission, SMI sells a 1991 reprint of the second edition https://bit.ly/mechanical-springs.

Local Spring Associations Flourish During the 1950s, local springmaker associations began to take root.

In 1953, the West Coast Spring Manufacturers Association was founded originally as the Pacific Spring Manufacturers Association. The association emphasized apprenticeship-training programs to educate new springmakers.

In 1957, the New England Spring Manufacturers Association (NESMA) was established in Connecticut. NESMA’s first president was future SMI president G. Donald Jacobson (1960-1962).

The exact year the Chicago Association of Spring Manufacturers, Inc. (CASMI) was founded is unknown. But the first CASMI show was in 1959.

It has grown into the popular Springworld expo. In 2024, SMI’s education conference will co-locate with Springworld in Rosemont, Illinois.

In 1962, the Spring Manufacturers Association of Canada was forged in response to Canadian Tariff Board hearings on spring industry matters.

The Mid-Atlantic Spring Manufacturers Association was created in 1981.

Over the years, many local spring associations have evolved and continue to be active, and some no longer exist.

SMA Becomes SMI In 1961, the Spring Manufacturers Association changed its name to the Spring Manufacturers Institute (SMI) to reflect its increased focus on technology.

Also in 1961, SMI president G. Donald Jacobson suggested that the institute establish a magazine dedicated to the spring industry with particular emphasis on spring technology. After much research and exploration, the idea became a reality. In May 1962, Volume 1, Number 1 of Springs: The International Magazine of Spring Manufacture was launched. (See one of the first Springs articles, “Flashback: Cavemen Made Own Springs,” on page 51).

Over the last 62 years, more than 240 issues and thousands of articles have been published specifically for springmakers. Springs is the voice of the spring industry connecting with readers across the globe in print, online (smihq.org/page/ springs_magazine), and through social media.

SMI Establishes Independent Office In 1969, George E. Underwood became SMI’s first full-time executive. He established an independent office for SMI in Bristol, Connecticut, and the association’s activities and membership grew significantly under his leadership. Before this, Underwood was both secretary of SMA and executive director of the Bristol Chamber of Commerce for almost 20 years.

Underwood’s association management also saw the continued growth of SMI activities. The Annual Market Summary was expanded to include data from non-member springmakers.

In 1973, Underwood retired. His successor, F. R. Downs, continued to expand SMI’s services to members, introducing management workshops and seminars and developing safety codes for the industry. He also promoted SMI’s participation in the Alliance of Metalworking Industries, a consortium of metalworking associations.

Boeing 707, first commercial jet, launches West Coast Spring Manufacturers Association founded 1949 1948

1951

1953

1950

1952

Korean War begins

First steel caster for carbon and low alloy billets built in England

32 Fall 2023 I Springs

1955 1954 Steve Jobs is born

New England Spring Manufacturers Association founded 1957 1956

SMA becomes SMI 1961

First Barbie doll is introduced 1959 1958

First Chicago Association of Spring Manufacturers’ show

Second edition of Wahl’s “Mechanical Springs” published Spring Manufacturers Association of Canada founded 1963

1960 Stelmor rod cooling conveyor developed

1962 First issue of Springs magazine published

1964

Vietnam War begins 1965 1966

Actor Ronald Reagan speaks at SMI summer meeting First commercial Stelmor operation completed “Handbook of Mechanical Spring Design” (Associated Spring)

SMI Charter Members On August 11, 1933, 40 charter members founded the Spring Manufacturers Association (now known as the Spring Manufacturers Institute). Twelve of those companies, highlighted in bold on this list, are still SMI members. Although some names, locations or ownership may have changed over the years, they can trace their roots to a name on this list.

ABC Spring Company, New York

W.B. Jones Spring Company, Cincinnati (Wilder, Kentucky)

American Coil Spring Company, Muskegon, Michigan (Michigan Spring and Stamping/Kern-Liebers)

Kline Spring Company, Cleveland

American Spiral Spring and Manufacturing Company, Pittsburgh

Kokomo Spring Company, Kokomo, Indiana

American Spring and Manufacturing Company, Holly, Michigan

L H D Spring Corporation, Waltham, Massachusetts

Lee Spring Company, Brooklyn F. N. Manross & Sons, Forestville, Connecticut

American Steel & Wire Company, Chicago The Wallace Barnes Company — Bristol, Connecticut (Barnes Group Inc./ Associated Spring)

Midwest Spring Manufacturing Company, Chicago (Mid-West Spring & Stamping Inc., Mentone, Indiana)

Barnes-Gibson-Raymond, Inc., Detroit (Barnes Group Inc./ Associated Spring)

Miller & Van Winkle, Inc, Brooklyn Muehlhausen Spring Company, Logansport, Ind. (MW Components — Logansport, Logansport, Indiana)

California Spring Company, Los Angeles Chicago Coil Spring Company, Chicago (MW Components Greer: Springs, Greer, South Carolina)

New Britain Spring Company, New Britain, Connecticut Newcomb Spring Company, Brooklyn (Alpharetta, Georgia)

Cleveland Wire Spring Company, Cleveland Cuyahoga Spring Company, Cleveland

Peck Spring Company, Plainville, Connecticut (Part of Economy Spring, owned by MW Industries)

Duer Spring & Manufacturing Company, McKee Rocks, Pennsylvania (MW Components Greer: Springs, Greer, South Carolina.)

Precision Spring Corporation, Detroit (Peterson Spring) Raymond Manufacturing Company, Corry, Pennsylvania (Barnes Group Inc./ Associated Spring Raymond, Maumee, Ohio)

Dunbar Brothers Company, Bristol, Connecticut Eaton Manufacturing Company, Detroit John Evans’ Sons, Philadelphia (Part of Lesjofors, Lansdale, Pennsylvania)

The Timms Spring Company, Elyria, Ohio

Chas. Fischer Spring Company, Brooklyn

United States Steel Wire Spring Company, Cleveland

General Spring Company, Cincinnati

Washburn Wire Company, New York

The Wm. D. Gibson Company, Chicago

Wickwire-Spencer Steel Company, New York (W.B. Jones Spring Co. Inc., Wilder, Kentucky)

United Spring Corporation, Brooklyn

Humason Manufacturing Company, Forestville, Connecticut Hunter Pressed Steel Company, Lansdale, Pennsylvania

Neil Armstrong walks on the Moon SMI opens independent office in Bristol, CT 1967

1969 1968

First Talking GI Joe action figure introduced

SMI Technical Membership formed with 26 suppliers 1971

1970 OSHA enacted

1973 1972

The Yost Superior Company, Springfield, Ohio

SMI office fire in Bristol, CT 1975

1974

1976

Revised SMI “Handbook of Spring Design” published 1977

First Electro­ magnetic stirring in continuous casting mold (M-EMS) 1979

1978

U.S. celebrates Bicentennial SMI moves office to Chicago area

1980

IBM unveils the first PC 1981

Gayle Sayers speaks at SMI annual meeting 1983 1982

Mid-Atlantic Spring Manufacturers Association launched

1985 1984

SMI turns 50 SMI publishes Fawcett’s “History of The Spring Industry”

Springs I Fall 2023 33

Fire Destroys SMI Offices On February 24, 1975, SMI’s office was destroyed by fire, but the association reportedly reopened for business within hours.

Of the fire, the May 20, 1975 SMI meeting minutes reported: “Another chapter in SMI’s history was written when, on February 24, (1975), the SMI office was the victim of a rather serious fire. Many records were destroyed or damaged by smoke and water. Virtually all the office machinery — due mainly to plastics and printed circuitry — had to be replaced. Files and furniture had to be refinished. Temporary quarters were set up in our Executive Vice President’s basement and garage.

The office was officially open for business by 1:30 p.m. the day of the fire.”

Downs continued to lead SMI until his retirement in 1979.

“History of the Spring Industry” Published In 1980, A.H. Petersen, Jr. suggested at a board meeting that SMI publish a book on the heritage of spring manufacturing in North America.

And so began the book project “History of the Spring Industry in the United States and Canada, “which served as a source for parts of this article.

A committee was formed with Petersen as the chair. After much discussion, the committee contracted W. Peyton Fawcett, head librarian at the Field Museum of Natural History in Chicago, to research and write the 189-page tome.

After hours of interviews and research by Fawcett, the book was published in 1983, coinciding with the commemoration of SMI’s 50th anniversary.

SMI Moves Offices to Chicago Before his retirement, Downs oversaw moving SMI’s office to the Midwest to be more centrally

1987 1986

1989 1988 Berlin Wall falls

1990

SMI reprints Wahl’s “Mechanical Springs” 1991

Tuner arm tension control for wire drawing introduced 1993

1992

1994

Soviet Union collapses

34 Fall 2023 I Springs

located. Since October 1979, SMI’s offices have been in the Chicago area, currently in Oak Brook, Illinois. Among the list of staff who worked out of the SMI Chicagoland office since 1979 as executive director were Patricia Williams and Ken Boyce.

In 1995, Lynne Carr began her remarkable 28-year career with SMI. She started as a parttime administrative assistant and was later named SMI executive director in 2013. In her decade as executive director, Carr helped implement many programs. Perhaps the most notable is SMI’s scholarship program introduced in 2010. See this year’s SMI scholarship recipients on page 44.

In early 2023, long-time Springs editor, Gary McCoy, took over the reins from Carr to become SMI’s new executive director.

Leaders’ Vision Guides SMI From the moment Fuller F. Barnes penned the letter establishing SMA more than 90 years ago, 37 presidents have served at the helm of SMI (see “Past Presidents” page 42). Along with these presidents have been countless committed committee members who have helped craft and implement programs to keep SMI vibrant and relevant.

Turn to page 40 for notes from several past presidents sharing memories and 90th birthday wishes to SMI.

SMI/UTS Develop Spring Design Application In 2002, Universal Technical Systems and SMI worked together in a joint effort to develop the Advanced Spring Design software. UTS combines expert engineering and custom calculations to help users design high-quality springs.

In the newest update, version 7.0, SMI’s Encyclopedia of Spring Design is now part of context-sensitive help. The embedded encyclopedia provides diagrams, tables and background on many variables involved in spring design.

SMI publishes three volumes of “Encyclopedia of Spring Design:” “Fundamentals of Spring Design,” “Compression, Extension, Garter and Torsion Springs” “Testing and Tolerancing”

Taiwan spring association visits SMI in Chicago Hong Kong returned to China 1997

1995 1996

1999

1998

“Design and Application of Helical and Spiral Spring” (SAE HS-795) published

2001 2000 9/11 terrorist attacks

2003 2002 2004 SMI & UTS launch “Advanced Spring Design” software SMI publishes “Encyclopedia of Spring Design: Other Spring Types” SMI revises “Handbook of Spring Design”

SMI’s Future is Bright Among the exciting new projects SMI is launching is the new “Springs Are Everywhere” podcast hosted by SMI Executive Director Gary McCoy. The podcast will feature interviews with business thought-leaders inside and outside the springmaking industry.

Springmaking continues to be relevant.

Whether the springs are used in traditional items such as automobiles, airplanes and appliances, or new products such as renewable energy or

eMobility, there’s no end in sight for the future of springs and related products in North America and across the globe. z Note: This account is based on various sources, including “History of the Spring Industry in the United States and Canada” by W. Peyton Fawcett, published by SMI in 1983.

Special thanks to C. Richard (Rick) Gordon for his input on technical milestones on the timeline.

Original SMI Associate Members SMI’s Technical Membership for spring manufacturing suppliers was established in May 1973, during Stanley Banas’ presidency. Today known as Associate Members, four companies highlighted in bold on this list, are still members. Some may have new names, locations or ownership.

American Spring Wire Corporation, Bedford Heights, Ohio

National-Standard Company, Niles, Michigan

Associated Spring Corporation, Wallace Barnes Steel Division, Bristol, Connecticut Bekaert Steel Wire Corporation, New York (Bekaert Corporation, Orrville, Ohio) Bendix Corporation, Industrial Tools Division, South Beloit, Illinois The Carlson Co, Oceanside, New York

New England High Carbon Wire Corporation, Millbury, Massachusetts Perfection Heat Treating Company, Chicago Precision Steel Warehouse, Inc., Franklin Park, Illinois Radcliff Wire, Inc, Bristol, Connecticut Seneca Wire & Manufacturing Company, Fostoria, Ohio Sleeper & Hartley Corporation, Worcester, Massachusetts

Continental Steel Corporation, Kokomo, Indiana AB Garphytte Bruk, Garphyttan, Sweden (Suzuki Garphyttan Corp., South Bend, Indiana)

Spring Manufacturers Supply Company, Forestville (Connecticut Swedish Wire Corporation, Muskegon, Michigan)

Gavlick Machinery Corporation, Torrington, Connecticut

Techalloy Company, Inc., Rahns, Pennsylvania

Gibbs Wire & Steel Company, Southington, Connecticut (Gibbs Interwire)

Teledyne Rodney Metals, New Bedford, Massachusetts Torin Corporation, Torrington, Connecticut (FENN/Torin, East Berlin, Connecticut)

Johnson Steel & Wire Company, Worcester, Massachusetts

Ulbrich Stainless Steels & Special Metals, Inc., Wallingford, Connecticut (North Haven, Connecticut)

Jones Metal, Inc. (J & S Metals, Inc.), Forestville, Connecticut Laclede Steel Company, St. Louis Lion Precision Corporation, Newton, Massachusetts

Brexit: UK votes to leave EU

2005 2006

Global financial crisis peaks

First SMI scholarships awarded

2007

2009 2008 75th anniversary convention in Palm Springs

Hurricane Katrina devastates Gulf Coast

Lynne Carr becomes SMI executive director 2013

2011 2010

2012

2014

SMI “Spring Fatigue Testing” program initiated SMI adds two more technical classes 2015

2017 2016

SMI adds one basic and two advanced tech classes

2019 2018

Springs marks 50 years, reprints first issue SMI launches tech class series with “Compression Spring Design”

2021 2020 COVID-19 pandemic begins

2023 2022

SMI Turns 90 Gary McCoy becomes SMI executive director SMI adds three more technical classes SMI launches “Springs Are Everywhere” podcast

Springs I Fall 2023 35

A History in Photos Equipment Evolution Springmaking technology has changed a lot since 1933, but the basic spring science remains the same as when A.M. Wahl first published “Mechanical Springs” in 1944.

36 Fall 2023 I Springs

1

Prominent Presenters There have been many notable personalities at SMI events. Pictured are actor Ronald Reagan (1 and 5), former Vice President Richard M. Nixon (3), spring expert A.M. Wahl with former SMI President Alex Rankin (2) and astronaut Story Musgave with SMI member Jay Dunwell (4).

2

3

4

5

Springs I Fall 2023 37

Informative and Entertaining Events and Tours Education, recreation, networking, friendship and family have been cornerstones of SMI meetings and overseas trips for decades.

2

1

1 Golf at an SMI annual meeting 2 Trip to Washington with Alliance of Metalworking Industries 3 Beach games at Hawaii SMI meeting 4 SMI committee meeting 5

3

SMI overseas trip

6 SMI staff attend black tie event 7 CASMI’s SpringWorld Expo in Chicago 8 Children have always participated in SMI events 9 Live entertainment at an SMI dinner 10 Taiwan springmakers group visits SMI in Chicago

4

38 Fall 2023 I Springs

5 9

10

6

7

8

See more archive photos in our anniversary playlist on YouTube. bit.ly/SMI-history

Springs I Fall 2023 39

90th Birthday Notes to SMI from Past Presidents

40 Fall 2023 I Springs

We asked the Spring Manufacturer Institutes’ past presidents and the current president to send birthday greetings to SMI for 90 years of excellence.

There were two reoccurring themes in the comments: the institute’s commitment to its mission and membership, and the members’ commitment to forging deep, enduring personal friendships and professional relationships. thday!

Dear SMI, your 90th Bir on s on ti la u Congrat ter with SMI y first encoun . I was I remember m nce higan confere at a 1982 Mic d, caring te n many tale t ee m to d se bles on, Chuck ng Bud Peters di u cl in , le op pe . That first d many others Whitchurch an desire to sion led to my positive impres serve SMI in various roles d get involved an reer. ca y m throughout d members h SMI staff an it w t en em lv Invo with great andy and me has blessed S d joy! friendships an

Few industry associations have survived and thrived for over nine decades. The commitment of the membership and the vision of the leadership has guided SMI through the years and toward the future.

So, put on your party hat, grab a slice of birthday cake and celebrate with us.

Blessings! eland Steven P. Mor Corporation ing Products pr S Automatic t 2012-2014 SMI Presiden

Happy Birthday SMI … being involved since 1989 and meeting so many new friends and acquaintances has shaped my professional career in the spring industry.

Here are greetings to SMI from a few of our current and prior leaders: Congratula tions on you r remarkabl 90-year jou e rney, SMI! As a past pr esident and CEO of a fo I’m profoun un dly gratefu l for the infl ding member, and growth uential net you’ve prov work ided to our The relation ind ships we’ve cultivated th ustry. been invalu roug abl excellence is e, and the shared comm h SMI have inspiring. itment to Here’s to the wonderful pe ople and the horizons we’ promising ll continue to explore to gether.

Steve Kempf Lee Spring SMI Presid ent 2018-2 020

SMI has provided countless opportunities to learn and network with fellow springmakers from around the country, all having different perspectives on common problems and challenges, yet working together for achievable solutions.

Also equally important, is how close SMI staff is engaged with all members and associates. I can’t say enough about how rewarding it has been to be a part of the leadership through various chapters in SMI’s 90-year history.

Happy birthday, SMI! You don’t look a day over 29!

Reb Banas Stanley Spring & Stamping SMI President 2008-2010 Springs I Fall 2023 41

SMI’s Past Presidents Fuller F. Barnes* 1933-1941 James W. Campbell* 1941-1943 Fuller F. Barnes* 1943-1946 Edward J. Byrnes, Jr.* 1946-1951 J.D. Culbertson III* 1951-1955 Harry C. Faust* 1955-1960 G. Donald Jacobson* 1960-1962 A.A. Bonde, Sr.* 1962-1964 L. Vaughan Barnes* 1964-1966 F.R. Downs, Jr.* 1966-1968 Hugh A. Purnell, Jr.* 1968-1970 A.H. “Bud” Peterson, Jr.* 1970-1972 Stanley R. Banas* 1972-1974 John B. Beckwith* 1974-1976 William M. Marsh* 1976-1977 Jack Bazz* 1977-1979 George C. Underwood II* 1979-1981 Steve Csonka* 1981-1983 Richard N. Witham 1983-1985 John R. Grace* 1985-1987 Edward H. Lanke* 1987-1989 Alex Rankin 1989-1991 M. Parker Blatchford 1991-1993 A.H. “Pete” Peterson III 1993-1995 G. Donald Jacobson, Jr. 1995-1997 Charles Pepka 1997-1999 Jim Zawacki 1999-2001 Roy Vinderine 2001-2003 Dave Weber 2003-2005 Dan Sebastian 2005-2008 Reb Banas 2008-2010 Scott Rankin 2010-2012 Steve Moreland 2012-2014 Hap Porter 2014-2016 Mike Betts 2016-2018 Steve Kempf 2018-2020 Bert Goering 2020-2022 Gene Huber 2022-2024 *Deceased

42 Fall 2023 I Springs

to SMI. Happy birthday e the chairman of th erday that I was e th th wi It seems like yest rk ittee and got to wo technology comm ed problems, lv so e W I. SM e of th n amazing brains a great foundatio ilt bu together and rld wo . e rs th be led em ve m tra r all hnical resource fo for SMI to be a tec was a high point the organization of t en id es pr g in Be in my career. e next 90 years!

Good luck over th Alex Rankin Mfg. Co., Retired Vulcan Spring & 89-1991 SMI President 19

to the spring community.

Congratulations SMI on 90 years of service survive the ravages You began 90 years ago to help springmakers bers in coordinating mem ted of the Great Depression and then assis World War II. After the g durin unity comm their efforts to support our technical support, war, you evolved again by providing education, gs magazine.

Sprin and a voice to the spring community through carts and a member You also entertain us with bears in our golf taking over a wine cellar.

Looking forward to the next 90 years!

Dan Sebastian MW Industries, Retired Springs Columnist SMI President 2005-2008

Dear SMI,

Congratu

A wonderful happy birthday to SMI! This all started for me as a kid going to “meetings” and truly getting to know the next generation of SMI leaders. We played in Hawaii and found our way to every 5-star resort we could imagine.

As the years progressed, we spent time together and became responsible adults. And our parents actually allowed us to run their successful companies. Even after our Bermuda trip (You had to be there!).

I’ve had so many friends from SMI and even lost some through the years, but it has made a huge path of memories that will be imprinted on me for life.

Thank you to the team that worked with me as president, Dan and Reb made my job easy and allowed us all to make great plans for SMI’s future.

I wish you a long future, SMI!

lations on turning th e BIG 90 th Not many is year! industry association of seniority s can claim downs” ov and the ability to s this level urvive all er the last the “ups a 9 0 years (g meltdown nd s, and pan lo demics, to balization, financi al name just Your impre a few). ss your abilit ive longevity can be attribu y ted to of serving to stay true to you r original your mem m ber compa them with nies by pro ission a viding and learn safe venue/format to p ing including . Your services spa romote education n an arra technical y of areas su safety top ics, develop pport, environmen t, health, a ment of in and keepin nd ternationa g l standard competitiv our U.S. spring m s anufactu e on a glo rers bal scale!

Keep up th eg of supporti ood work as you en te ng our in dustry’s n r your tenth decad e eeds!

Bert Goeri ng Precision Coi SMI Presid l Spring ent 2020-2 022

With gratitude for all involved.

Scott Rankin Vulcan Spring & Mfg. Co. SMI President 2010-2012

Happy birthday to SM

I! Congratulations to all of the members, friends and children of friends in the organization.

We’re still a viable energ y option for the future!

Chuck Pepka Renton Coil Spring Co . Inc. SMI President 1997-19 99

I! th Happy 90 birthday, SM ny years has been a joy Following SMI for ma ry forward to receiving eve in my life, and I look issue of Springs! t eged to serve as presiden I was honored and privil e, tim t tha g 85. Durin of SMI from 1983 to 19 ers. The number one mb me its d ye SMI surve ll the next generation of wi question was, “Where the m?” I bet that it is still springmakers come fro o ag ars ye s son o d my tw number one issue! I tol can y the all do le, sib es pos to hire the best employe ryone with respect and eve at tre m, the rt ppo to su ryone. expect the best from eve unique as it allows all The spring industry is ss. ate creativity and progre employees to demonstr key part of my career.

Thank you for being a

Happy birthday, SMI! Celebrating the milestone of 90 yea rs as an association is amazing! The only thing that can be said is, “Keep up the hard work and dedication to the ind ustry that you have always shown,” and let’s go for another 90 years!

Gene Huber Winamac Coil Spring Current SMI President 2022-2024

Dick Witham Motion Dynamics, Motion, Retired Automated Industrial 85 SMI President 1983-19 Springs I Fall 2023 43

Ten Students Receive $23,000 in Aid Through

By Gabriela Carrasco

t is no secret that “ Imedical school is expensive and inaccessible for many, so there is no understating how much SMI’s gift will facilitate my journey!

” —C onnor Burrows, Zeeland, Michigan

I

n another successful year for the scholarship program, $23,000 in financial aid was distributed to 10 students among a pool of applicants from SMI’s members in the U.S., Canada and Mexico. This program has awarded $357,500 since its beginning in 2010 and has served 167 students.

“Our commitment to education goes beyond SMI’s core objectives,” said SMI president, Gene Huber Jr. “We firmly believe in investing in the potential of young talent and providing them with the resources they need to thrive. SMI’s Scholarship Program is our way of supporting and empowering these exceptional students, as they possess the capability to create a lasting impact in their respective fields.”

To be eligible for an SMI scholarship, award winners must be a fulltime employee or a dependent child of a full-time employee who works for an SMI member company.

In 2023, SMI awarded five regional scholarships in the amount of $2,000 each. In addition, five at-large scholarships were selected: • Ronald and Adrienne Banas Scholarship, $5,000 • International Spring Scholarship, $4,000 awarded to two students in the amount of $2,000 each • Callaghan-Hart Scholarship, $2,000 • The Gibraltar Company Scholarship, $2,000 SMI member companies will receive information for the 2023 scholarship program in the fall, via email and on SMI’s website, www.smihq.org. z

scholarship will “ This help me pursue an education in my dream field.

”

— Arika Warren, Silver Lake, Indiana

44 Fall 2023 I Springs

the 2023 SMI Scholarship Program 2023 Regional Scholarships

2023 At-Large Scholarships

Canada

Roland and Adrienne Banas Scholarship Saumya Mathur Hometown: Pickering, Ontario SMI Member Parent: Rajiv Mathur, Bohne Spring Industries Ltd. Attending: University of Toronto Major: Cell and Systems Biology

U.S. Anna Gruchala Hometown: Clarendon Hills, Illinois SMI Member Parent: Grzegorz Gruchala, Sterling Spring Attending: University of Alabama Major: Environmental Engineering Carrie Lefeber Hometown: Van Dyne, Wisconsin SMI Member Parent: Christine Lefeber, Spiros Industries Attending: University of Wisconsin-Platteville Major: Mechanical Engineering Lily Shane Hometown: Dallas, Texas SMI Member Parent: Aki Shane, Newcomb Spring of Texas Attending: University of Texas at Austin Major: Radio-Television-Film Arika Warren Hometown: Silver Lake, Indiana SMI Member Parent: Kristopher Warren, Midwest Spring and Stamping Attending: Taylor University Major: Sports Management

scholarship amount, “ The and the recognition showered by

Leah Pennington Hometown: Randolph, Mississippi SMI Member Parent: Christy Pennington, MW Components Pontotoc Springs Attending: Mississippi State University Major: Communication

International Spring Scholarship John Babu Hometown: North York, Ontario SMI Member Parent: Francis Babu, Commercial Spring and Tool Co. Ltd. Attending: Michener Institute Major: Medical Lab Science

International Spring Scholarship Tomasz Gruchala Hometown: Clarendon Hills, Illinois SMI Member Parent: Grzegorz Gruchala, Sterling Spring Attending: Northwestern University Feinberg School of Medicine Major: Medicine

Gibraltar Corp. Scholarship Calli Dussia Hometown: Cleveland, Tennessee SMI Member Parent: Adam Dussia, Newcomb Spring Attending: Tennessee Wesleyan University Major: History: Secondary Education

Callaghan-Hart Scholarship Connor Burrows Hometown: Zeeland, Michigan SMI Member Parent: Bradford Burrows, Automatic Spring Products Corporation Attending: Michigan State University, College of East Lansing Major: Doctor of Medicine

a prestigious company like the Spring Manufacturers Institute, is particularly heartwarming. This award will go a long way in helping me support my education.

”

— John Babu, North York, Ontario

Springs I Fall 2023 45

Using Force Measurement vs Material Testing

By Jacob Morales

Much of the testing for many types of spring products requires force measurement of samples to verify if they are able to meet the specified load/deflection requirements.

However, throughout the material manufacturing process, material testing using the tensile test is used to characterize material properties and determine if the material meets the specification requirements.

This article will describe the differences between the two types of tests — force measurement, a non-destructive test, and material tensile testing, a destructive test.

Your choice can be simplified by knowing what kind of information you need to collect.

The Difference in Units

New Starrett Rapid Change Spring Force Fixture allows operators to quickly switch between test springs and load cells.

First, it is helpful to understand the difference in units. Force/deflection testing is used to determine a spring’s conformance to specification requirements. Loads are commonly measured in values of pounds-force (lbf) or newtons (N), while height or travel is measured in distance units such as inches (in.) and millimeters (mm). In material testing, force measurements are converted to stress by knowing the sample’s cross-sectional area.

The units of measure for stress are pounds per square inch (lbf/in.2 or psi) or megapascals (N/mm2 or MPa). The units of measure for strain are dimensionless (inches per inch or mm per mm) and are expressed as a percentage. The key difference between these two-unit sets is that stress and strain are determined from the properties of the material sample itself, rather than just the load being measured at specific deflections.

The following examples are designed to explain in the simplest terms the concept of stress for two non-spring materials.

Common Units in Test Graphing Based on Testing Type X Axis

Y Axis

Force Testing

Millimeters (mm), inches (in)

Newtons (N), Kilonewtons (kN), Gram-force (GF), pounds force (lbf)

Material Testing

Unitless, or a Percentage (%)

Pascals (Pa), Megapascals (MPa), Pounds per Square Inch (psi)

46 Fall 2023 I Springs

Consider breaking a cube in half in a uniaxial force tester operating in a perfect system where objects don’t deform under tension. The test is designed to hold the sample by opposing faces, applying a tensile force to break it in half. The resulting halves would be perfect square prisms, each half the height of the original cube. A force test assumes that the size and shape of the cube are irrelevant — either because all of the cube samples are uniform in dimension so that the size and shape would not matter, or the difference in sizes is unimportant as long as the cube reacts properly to the loads being applied. As a result, it would be unnecessary to test in stress and strain values and instead measure in load and distance.

A material test, however, requires knowing the cube’s dimensions to properly report its findings.

Consider a test sample, sample #1. Let’s assume the cube is one inch long on each edge, and it takes 100 pounds of force to break it in half. For a force test, the 100 pound-force value is all that’s required for the force system to collect as a data value, but for a material test, the system needs to translate that information to psi. Because it is a perfect cube breaking evenly in half (without stretching), the cross-section is one inch by oneinch square. To determine the stress at break, the 100 pound-force is divided by the cross-sectional area of 1 square inch, which equals 100 poundforce per square inch, or 100 psi.

To help put this into context for factoring in variables when material testing, let’s look at sample #2, a larger cube composed of a different material. In this case, we have a cube with twoinch edges made of a different material that also breaks at 100 pounds-force. Now that the cube is bigger, so is the cross-section, which is now two inches by two inches, or four-square inches. When

dividing the 100-pounds force by that area, the result is 25 psi. It is a lower stress value — indicating a generally weaker material.

Consider that the area of material #2 where the break occurs is four times the area of material #1, but still breaks at 100 pounds of force. If you had a cube of material #2 that was one inch on each side, like the first one, you can assume that it would break at a lower load value. You can even estimate that breaking load value: 25 psi times 1 in2 is equal to 25 pounds. For a cube of material #1 but now with dimensions of two inches on each edge, the calculated breaking load would be 400 pounds-force; 100 psi times 4 in2 equals 400 pounds.

The example provided ignores many realworld behaviors for simplicity, but the general application is similar — material tests determine the inherent properties of what is being tested.

The equipment needs to be scaled appropriately for when the samples change size so that they collect information accurately. A force test does not require that information and can note behaviors under load without needing the material sample test data.

Force Testing Examples One of the better examples of a consistently manufactured product that must conform to specific force application and displacement standards is wire coil springs, made for either compression or tension. Figure 1 shows an example of a typical spring load testing machine.

When testing, springs are most often checked to see if they compress or extend an appropriate distance to determine if their spring rates (in units of force per distance such as lbf/in, or N/mm) meet the design requirements. Because of the consistency in their properties, there’s not much of a need to include the material properties when testing the load/deflection of a spring. Material properties of the wire used to form the spring are instead measured and certified for conformance to the specification by the wire manufacturer or service center. Material testing, because it is a destructive test, is more appropriately performed

Fig. 1. Load — deflection testing of a compression spring.

Fig. 2. Tensile testing of wire or strip samples.

on the raw wire or metal samples1, rather than performing the material testing on the wire from the fully formed spring.

In the case of springs, force testing often involves testing an item’s functionality instead of its material properties. Take, for example, the need to test a button or a switch. Other manufactured parts typically have uniform designs, so testing a minimum required force rather than stresses across the component surface is simpler to perform. Some examples include syringes for both plunger testing and puncture testing, as well as packing material for strength — either for bubble wrap or airbag packaging to test for minimum popping force, or foam compositions for breaking strength under load.

Material Testing Example — Wire Testing The metal properties of the spring’s uncoiled wire can be assessed through the analysis of stressstrain testing. Unlike when it’s in coiled form, the lengthwise testing of wire gives an easier means to determine the cross-sectional area upon which the stresses are applied, which for round wire is equal to the area of the circle defined by the wire diameter. It also allows for proper elongation measurement, as it occurs along the sample’s whole length where appropriately gripped (see Figure 2).

Springs I Fall 2023 47

A Starrett Long Travel Extensometer is used to accurately calculate elongation based on the overall distance moved, critical to prevent structural failure of highly elastic materials.

Fig. 3. Schematic diagrams showing the operating principles of different types of extensometers2.

Using the raw wire instead of the wire from a coiled spring provides an additional advantage.

For applications where high precision is required, an elongation measuring tool called an exten­ someter can be used.

Primarily, extensometers are used to determine yielding behavior, i.e., 0.2% offset yield strength of the material. There are two basic types: contact and noncontact.

In Figure 3, schematics of two extensometers are shown: contact types include clip-on (left) and sensor arm (right) Output signals from each type of extensometer are input to the testing machine process computer for documentation, calculations and reporting.

Clip-on type extensometers are designed to grip the samples at fixed points and measure the change in distance between two points as the sample stretches. Once the material’s yield point is reached, the tensile test is stopped and the extensometer is removed. Sensor arm extensometers can measure elongation up to the final fracture.

For example, suppose an extensometer has grips with an initial separation of one inch, and the

48 Fall 2023 I Springs

sample stretches to further separate them by an additional half inch. In that case, the test recording will note a fifty percent increase of sample length or elongation. The extensometer design often considers the intended sample material, and it is constructed with physical limits to their maximum travel distance.

Depending on the extensometer, these travel limits might be shorter than the full-length of a test stand, but well within the expected limits of elongation based on material ductility. Integrated extensometer units can operate with the test system’s software, while independent units can be specifically configured for the material type.

For example, longer elongation devices may be used for highly ductile samples, and more durable, though shorter elongation models are appropriate for less ductile samples to stay on the sample through its break. z

References 1. Gordon, C.R., Types of Tests Used to Characterize Springmaking Materials, Springs, Winter 2020, p.27-31.

2. W. Becker and M. Dripke, Choosing the Right Extensometer for Every Materials Testing Application, Advanced Materials and Processes, Vol. 169, No. 4, (2011), p.17-21.

Fig. 4. Graphical output for a compression spring load test.

A spring compression (load) test. The spring follows a linear compression and reaches a maximum load at approximately 350 pounds for one sample and 500 for another. Pressure testing is not required for this test, and elongation is not calculated, so the stress/strain values are not graphed.

Jacob Morales has been with The L.S. Starrett Company for more than four years as a technical support engineer for the company’s Force and Material Testing Equipment division. Prior to Starrett, he was with Hutchinson Sealing Systems, involved with component manufacturing in logistics and product compliance/quality testing roles. Morales holds a bachelor of science degree from Rensselaer Polytechnic Institute and MBA from Southern New Hampshire University. You can reach Morales at (978) 249-3551 For more information on Starrett Force Systems, visit starrettmetrology.com/force

Fig. 5. Graphical output for a material tensile test.

A material tensile test progresses to sample break, determining the maximum stress (εmax) and the strain value at that point (ε@max). A cross-sectional area and gage length was provided for the controller to calculate the stress from the load and the strain values. The load at maximum stress (L@max) and travel distance at that point (D@max) are calculated from these values.

Force and Material Test Applicability Checklist: Commonly Collected Information Requirement

Force Test

Material Test

Distance measurements

Not always. Sometimes requiring applied load measurements only.

Not always. Sometimes requiring stress measurements only.

Requires Extensometers

No (Extensometers are used for strain evaluation in Material Testing)

Sometimes. (Extensometers are used for strain evaluation)

Required Results include pressure values (psi, MPa)

No

Yes (this is a strength test and is measured in the same units as stress (psi, MPa).

The L.S. Starrett Company offers uniaxial force testers and material testers designed for force application and data collection. However, there are different levels of controller software, depending on the sample testing requirements.

The list above indicates a few parameters where the Starrett L3 controller software for material testing would be more convenient than the standard Starrett software suites, such as L1 or L2+.

Springs I Fall 2023 49

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Flashback Cavemen Made Own Springs Springs are almost as old as mankind. Cavemen hurled stones by fastening them to flexible saplings. Crude weapons employing this principle but using elastic leather thongs and iron rings appeared in ancient Syracuse about 400 B.C. Philo of Byzantium is credited with discovering the elasticity of metal in the second century. The medieval crossbow is really a spring.

Even in antiquity, springs served, just as they do today, to store mechanical energy, and release it according to plan — in the form of push, pull or twist — upon the specified occurrences.

Springs are not often seen, but without them, there would be no automobiles, airplanes, guided missiles, atomic reactors, automatic washers, dryers, refrigerators, timers, toasters,

coffee makers, machine tools, typewriters, electronic computers, musical instruments, campaign buttons, clipboards, television, printing presses, guns, bombs, mechanical toys, clocks, instruments, safety pins, locks, electricity or anything employing automatic action.

Springs as we think of them today first appeared about 1450. One of the earliest known applications was in the famed "Nürnberg Eggs” actually very early spring-motivated clocks. Pepys in 1665 participated in a trial of springs to ease the discomfort of riding in carriages, and, incidentally, to cut the annual claims for damage to freight against the Shrewsbury Coach from £6600 to £43.

Springs have been reducing costs ever since! By 1780 Joseph Bramah of Yorkshire had taken out 18 patents on spring-making machines. Springs for furniture were patented first in Britain in 1826.

The father of the modern coiler was Clinton Marshall who built his first for Washburn and Moen in 1892. A leading American spring manufacturer traces its beginnings to Edward Dunbar who started making clock springs in 1845 at Bristol, Connecticut. Certainly, every new apprentice in a modern spring plant soon hears about the part the making of hoops for women's skirts played in building the mechanical spring industry as we know it today. z

by Harman McBride

Editor’s Note: Keeping with our historic theme, we flashback to May 1962 and the first issue of Springs.

In “Cavemen Made Own Springs.” Harman McBride gives us a compressed history of springs pre-SMI. Harman founded The Reliable Springs and Wire Forms Company, in 1937 with $2,500 and four employees, says his son, Richard McBride, the current president. During World War II, “Reliable became a supplier of hand grenade springs and other wireforms, springs and stampings for the Defense Department,” Richard said. In 1990, Reliable moved from Cleveland to a 34,000 sq. ft. plant in Elyria, Ohio. Harman died on April 11, 1996, at the age of 81.

Springs I Fall 2023

51

Five Questions Five Questions allows SMI associate members to tell the spring industry about their products and services. In this edition, we talk with Michio Takeda, North American representative for…

Asahi-Seiki Manufacturing Co. Ltd.

1

Can you tell us about the history of Asahi-Seiki Manufacturing Co. Ltd.?

In 1953, Asahi-Seiki began in the specialized field of small ammunition production for the Japanese defense forces. With their munitions experience, Asahi-Seiki developed a wide range of advanced technologies for metal processing.

In the 1960s, they started manufacturing transfer press machines for precision metal components using a deep drawing process technology. In the 1970s, they began building CNC springforming machines.

Their processing and control technologies are used to make aircraft parts for the Boeing 787 (the Dreamliner). Asahi-Seiki equipment has made the “honeycomb” inside the 787 fuel tank since the first Dreamliner launched in 2010.

2

What types of equipment does Asahi-Seiki produce?

Our transfer presses are designed for mid-size operations ranging from 25 to 100 tons. We specialize in building CNC multi-forming and CNC spring-forming machines, such as coilers, torsion and extension spring units. Our automatic assembly machines are perfect for high-speed assembly and inspection, while our sorting conveyance unit is a popular choice in the physical distribution industry.

3

What are the latest trends in springmaking and wire-forming equipment?

The Asahi-Seiki CNC spring former, Model T2 (2 mm wire size; T4, 4 mm wire size), combined with several optional units, gives the user greater freedom in customization.

The central unit is a universal forming slide.

Our three-axis unit can attach right and left coiling and forming tools. Complex forming can be performed with fewer tools, and setup time can be significantly reduced.

The TRES universal unit has a five-axis multifunctional unit with three forming functions. The assist slide is a two-axis table unit that makes the free placement of spinning, cutting and other additional functions possible. The optional cutting unit eliminates burrs. And finally, the wire rotation device allows the wire and wire guide rotation, making complex forming processes easier.

4

What unique accessories or services do you offer spring makers?

We produce spring-end grinders and automatic down-feed grinding machines with servo motors.

5

Can you tell us about a recent challenge that you were able to solve for a customer?

In April 2023, a customer’s shipment of replacement parts was held by U.S. Customs due to an import license requirement, even though they had never needed one before.

With my airline cargo experience, I found the appropriate FedEx specialist who told me the commodity code was wrong on the commercial invoice. I immediately requested a revised invoice from Asahi-Seiki and they promptly responded. The shipment cleared customs and was quickly delivered to my customer.

I was contacted Friday morning about the issue (Saturday in Japan). By Monday afternoon the shipment was delivered. The customer repeatedly thanked me for my help and the minimal spring machine downtime. ❚

Michio Takeda 武田倫生 Asahi-Seiki Mfg. Co. North America Rep Office 390 Sherwood Drive Carol Stream, IL 60188 Phone: 847-736-5566 michiotakeda@comcast.net www.asahiseiki-mfg.co.jp

Follow SMI on social media for bonus content on Michio Takeda and Asahi-Seiki.

Springs I Fall 2023 53

Springmaker Spotlight

By Gary McCoy, Executive Director

Springmaking pioneers in the mid 1800s forged a new industry by inventing and manufacturing innovative types of springs for suspension, upholstery and mechanical use.

54 Fall 2023 I Springs

Early Pioneers Long before 1933, when an association for the spring industry was formed (that we celebrate in this issue), the roots of a formal industry for making springs can be traced back to the 1850s. It’s a period of time that W. Payton Fawcett cites in his book, “History of the Spring Industry in the United States and Canada,” as a “key period in the history of the springmaking industry in the United States.”

Fawcett says prior to the 1850s, “springmaking only existed as an adjunct to other industries, such as clockmaking.”

A rising tide of industrialization saw the invention of new products, some of which utilized spring action and required the manufacturing of several spring types, including suspension, upholstery and mechanical. Early industries utilizing these types of springs included railroad companies, upholstery and bed manufacturers and clockmakers.

In this edition of Springmaker Spotlight, we review the history of two legacy manufacturers in the spring industry.

John Evans’ Sons According to Fawcett, “On March 8, 1850, John Evans, founder of John Evans’ Sons, Inc., opened his business in New Haven, Connecticut, manufacturing flat springs for carriages and other vehicles, as well as the machinery to manufacture the springs.”

Evans, a Welsh blacksmith, came to the U.S. in 1847. Fawcett said Evans believed in diversification. “Among his successful ventures were the design of the first horse-drawn coal wagons using the gear-and-lever principle to raise the bed of the wagon to unload by gravity, and the development of hydraulic shock absorbers, on which he held the original patents.”

According to the company website for John Evans’ Sons, Evans always had ambitions to stand out from other spring manufacturers. “In contrast to some manufacturers of the era who formed spring steel solely for the immensely popular ‘hoop skirt,’ John Evans was thinking about ‘diversification.’”

In Fawcett’s book on the history of the spring industry, he points out that, “In 1852, Matthias Shoemaker founded the Philadelphia Spring Works in that city and began to manufacture carriage springs. Sometime later, Mr. Shoemaker replaced his original machinery with Evans’ equipment.”

Shoemaker later convinced Evans to move his business to Philadelphia, “citing their parallel interests.” Evans moved to Philadelphia in 1870 and set up shop next door to Shoemaker at 506 N. 13th Street.”

John Evans, circa 1850

Under the guidance of Charles Shoemaker, who later became president of the company in 1936, the firm moved into the production of precision springs, wireforms and metal stampings in 1928.

It is noted on the company’s website that as the country faced two world wars, John Evans’ Sons, Inc. contributed heavily to the war efforts and thus changed the focus of its products. “Manufacturing

Among his successful ventures were the design of the first horse-drawn coal wagons using the gear-and-lever principle to raise the bed of the wagon to unload by gravity, and the development of hydraulic shock absorbers, on which he held the original patents.

Springs I Fall 2023 55

Springmaker Spotlight

John Evans’ Sons original Philadelphia plant at 506 North 13th Street. The plant was in continuous production from 1870 to 1967.

small, delicate springs used in oxygen equipment control valves for military aviators, the business turned toward the specialty spring market and away from ‘off-the-shelf’ products.”

The company continued to evolve, producing precision springs for such commercial products as toasters, fishing reels and movie projectors, while maintaining a relationship with the U.S. defense industry after the second World War.

In 1967 the company was purchased by G. Delmar Bennett and moved to a modern facility in Lansdale, Pennsylvania. Fawcett noted that Bennett had previously been associated with Hunter Spring Company. Bennett, along with sonin-law’s Allan and Frank Davey, significantly grew the company investing in capital equipment and building expansion.

Sam Davey and Pate Banmiller, third generation family members and employees from the late 1990s, purchased the company in 2016 and drove growth with investments in technology and automation. John Evans’ Sons was acquired in 2022 by Lesjöfors, part of the Sweden-based Beijer Alma group.

As the company said in a news release, “John Evans’ Sons is the oldest springmaker in the U.S., founded in 1850, and has a leading position on the U.S. market. The company has a diversified customer base with long customer relationships, attributable to its expertise and ability to support customers early in their product development projects. Revenue mainly stems from customers within the medical industry but also customers within the industrial, construction, aerospace and transportation industries.”

As the former owners and co-presidents of John Evans’ Son, Davey and Banmiller, remain in their operational roles for continued business development.

At the time of the acquisition, Davey and Banmiller said they were thankful for two prior family generations who successfully ran America’s oldest springmaker.

“Since joining the business in the late 1990s, we have cultivated relationships with our world-class customers and been the recipients of exceptional raw materials and services from our vendors,” said Davey and Banmiller. “Far and away, the biggest contribution to the company’s success has come from our talented workforce and their ongoing pursuit of technical and manufacturing excellence.”

For more information, visit springcompany.com.

Far and away, the biggest contribution to the company’s success has come from our talented workforce and their ongoing pursuit of technical and manufacturing excellence.

56 Fall 2023 I Springs

Betts Company Not many family-owned and managed companies survive to the sixth generation. Betts Company is one of those survivors.

Since 1868, Betts Company has evolved from its humble beginnings as the first spring manufacturer west of the Mississippi into a diversified operation that serves heavy-duty transportation, automotive aftermarket and other industrial sectors.

Betts Company’s legacy began during America’s postwar reconstruction era. Ingenuity was flourishing, and tradesmen were immigrating to the USA. Among them was William Michael Betts, an English ironworker who wanted to pioneer spring manufacturing in the west. With a bold move to San Francisco, young William launched his namesake company that quickly became known for expertly crafting springs for wagons and buggies of all kinds. Along the way, Betts’ reputation for quality, integrity, and ingenuity was built.

“We simply listen to customers, for they know more about current requirements and future trends than any other element of the supply chain,” explained Betts Company (as the company is now known) William Michael “Mike” Betts IV in a 2009 Springs interview.

Betts is the fifth generation to lead the company and now serves as chairman. His son, William Michael “Bill” Betts V, leads the company as its president. That makes it six generations of continuous family ownership and management for Betts Company.

“Our philosophy is to provide an energizing environment where our associates are empowered and feel part of something special — a winning team. This energy provides the impetus for excellence in execution,” said Betts in the 2009 interview.

Betts’ great, great grandfather learned the trade of springmaking in London, England. In 1868, three years after the Civil War ended, he forged west to San Francisco and opened his shop, making leaf springs for carriages and wagons.

William Michael Betts

Betts’ workers in San Francisco in the mid 1800s.

Springs I Fall 2023 57

Springmaker Spotlight Betts Company was recognized in its infancy for quality manufacturing, being awarded a gold medal in 1871 at the Mechanics Exhibition in San Francisco for the manufacture of superior carriage springs.

Betts Company has proven resilient through significant challenges and obstacles. The Great San Francisco earthquake and fire destroyed the company’s sole facility in 1906. Betts’ greatgrandfather Percy helped rebuild BSC and guided expansion into the production of coil springs for locomotives, automobiles, trucks and tractors.

Percy tragically died at an early age in 1919. The company was blessed that Percy’s wife and Mike’s great-grandmother, Emeline Betts, was a woman of rare strength and fortitude. Cast into the role of president without formal training in a maledominated business, Emeline led the company through the Great Depression. At a time of unprecedented financial hardship, Betts Company not only survived but grew – lessons well learned and remembered during today’s challenging times.

Betts Spring employee during the late ’40s feeding iron into furnace.

John Tate, Betts Spring employee, cold tapering spring, late ’40s.

Betts Spring display at California Expo in Sacramento, California, late ’40s.

58 Fall 2023 I Springs

We simply listen to customers, for they know more about current requirements and future trends than any other element of the supply chain.

During its history, Betts became known as an industry leader for creating innovative, patented products made in the United States. A continuously family-owned business for six generations, Betts Company’s core values, known as The Betts Way, have been the guiding principles that inspire the company to Improve the Way Things Move® for customers, suppliers, and the communities in which it lives.

Today, Betts Company proudly serves the transportation and other industrial markets through its three business divisions–Betts Spring Manufacturing, Betts Truck Parts & and BettsHD. For more information, visit betts1868.com.

As we celebrate the 90th anniversary of SMI, the spring industry is fortunate to have many legacy companies like John Evans’ Sons and Betts Company that continue to serve their customers and provide jobs and opportunities to many employees. z

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Betts’ advertisement (circa 1948).

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Springs I Fall 2023 59

Women in Springs Labor and Love

By Sara Scullin

Linda Froehlich, CEO of Ace Wire Spring & Form Co., on Finding Family, Passion and Purpose in Springs

Linda Froehlich

Linda’s grandfather, Joseph Vodvarka Sr

60 Fall 2023 I Springs

Linda’s father, Joseph A. Vodvarka

Springs have always been a part of Linda Froehlich’s world.

Froehlich’s father, Joseph Vodvarka, started the business in 1939. In 1976 she and her husband, Richard, purchased Ace from her father. In 1986 they built their third building and moved to McKees Rocks, Pennsylvania, where Ace operates today out of a 55,000-square-foot facility.

When Richard passed in March 2022, Froehlich and her son Ritch continued moving the business forward. Recently, her granddaughter, Tresslyn and grandson, RJ, joined the company after graduating from college.

“A lot of buyers like dealing with family-owned companies,” Froehlich says. “They like knowing us and working with us because of our excellent reputation in the industry. We’ve also been blessed with the greatest employees, many of whom have been with us for 30, 40 or 50 years.”

Froehlich has always seen women at work.

Her mother and grandmother supplied parts to Rockwell International while her father served in the Air Force as an airplane mechanic during World War II. Early on, two of her aunts worked in the office with her dad. They were a great inspiration to her. Froehlich began helping with filing and other tasks at age 14, and continued working with the company as a young wife and mom.

Even back then, Froehlich says, to be a woman in the industry required extra coordination and tenacity.

“For a short time, my mom watched our son while we worked long hours,” Froehlich says. “Then, when our daughter was born six years later, we hired a full-time nanny who was great with the children.

“I don’t know how some women do it today,” she says. “They and their partners drop the dog

off in the morning, drop the kids off at day care or school, then they do it all in reverse after a long day at work. Not to mention driving to practices, making dinner, helping with homework and getting the kids ready for bed.”

For a long time, it was uncommon to see a woman in a manufacturing leadership role, especially in a male-dominated industry like springs.

This has begun to change in the last decade or so, and Froehlich says, “That’s a good thing.”

“I think it was an advantage for me to be in the industry, work trade shows and talk with engineers. A lot of times, they would look at my manufacturing rep and want to talk with him about our products or a design question they had, and the rep would say, ‘Don’t ask me, ask her; she owns the company. ’ But fortunately, that’s changing.”

Froehlich and her team stay at the forefront of innovation by keeping a diverse portfolio, investing in new technology and utilizing digital and social media platforms.

From early on, she prioritized learning about new technologies and different industries worth pursuing. She views industry conferences and organizations as invaluable sources of information and community, particularly when many companies grapple with whether to sell, dissolve or change course.

“You’re still trying to keep those connections in the search for new technology, and do business with forward-thinking companies and vendors,” Froehlich says, She’s also made lifelong friends at organizations like the Spring Manufacturers Institute (SMI).

These days Ace’s biggest challenge is not keeping pace with technology but hiring and retaining employees. It’s a big reason why Froehlich partners with local trade and technical schools to educate students about the rewarding careers they can find in this industry.

“A lot of people think of springs as a commodity,” she says, “But they are an integral part of whatever product a company makes.”

Looking ahead, Froehlich is excited to see the establishment of SMI’s first Women’s Business Committee: “If you’re reading this

Current family members on staff at Ace Wire Spring & Form. Center: Ritch B. Froehlich, back row (l-to-r): RJ, Tresslyn, Taytem and Linda Froehlich

article and work in a spring or wireform company, please reach out to us and get involved,” she says. “We want to hear from you!”

To her fellow women just launching their careers in manufacturing, she offers this: “Be prepared to work a lot harder. And don’t give up.”

“It's been my life,” Froehlich says of Ace, springs and industry friends. “It’s been a rewarding and meaningful career, and you really can't ask for more than that. You have to love what you do and have the passion to keep it going, and then pass that passion on to your family and your employees.” z

It’s been a rewarding and meaningful career, and you really can’t ask for more than that.

Springs I Fall 2023 61

CTE News

By Phil Sasso

Michigan’s MiCareerQuest Features Three SMI Members MiCareerQuest, organized by the nationally recognized West Michigan Works, was held at DeVos Place in Grand Rapids, Michigan, May 24. The 2023 event allowed nearly 9,000 middle and high school students to explore in-demand careers in agribusiness, construction, health sciences, information technology and advanced manufacturing. It was the first in-person MiCareerQuest event since the pandemic.

Within the advanced manufacturing career track area was a section featuring SMI member companies Wolverine Coil Spring Co. and Scherdel Sales and Technology, along with SMI associate member A.I. Technology, the north american distributor of Itaya springmaking machinery.

The collaboration between the three companies showcased the latest advancements in spring manufacturing technology. The interactivity drew considerable interest to the exhibits,

Counterclockwise from top left: Nicholas Waitz shows student how to run an Itaya MX20B. Students wait in line at spingmakers’ booth. Team from Wolverine, Scherdel and A.I. Technology. Facing page: Students ask questions and explore springmaking, including playing a “springshot” game.

62 Fall 2023 I Springs

demonstrations and activities designed to engage young minds.

A major highlight was an Itaya MX20B CNC machine operated by 12-year-old Nicholas Waitz under the watchful eye of his father, Ryan Waitz, a technical engineer from A.I. Technology. Nicholas masterfully explained the machine’s intricate operations to students in easy-to-understand language. Kids enjoyed choosing one of three spring shapes they wanted, watching the Itaya machine form it and holding the warm part in their hands that they had just fabricated.

“It was Nicholas’s first year being part of the exhibit team at MiCareerQuest,” said Ryan Waitz.

“And I expect him to be at many more to come.”

“Nicholas knocked it out of the park,” said Jay Dunwell, president of Wolverine Coil Spring.

“I want to thank everyone for their support of MiCareerQuest. It was another successful year, and great to be back to in-person career exploration … students and guests certainly had the chance to see some very cool things, including that very impressive Itaya machine with such a skilled technician.”

One of the other popular hands-on attractions was “springshot,” where students could launch a ping pong ball at a target using a spring-loaded slingshot.

“The ‘springshot’ game attracted quite the line of eager participants who greatly enjoyed making the siren go off and the lights flash,” said Dunwell.

“Special thanks to Wolverine and Scherdel employees who deserve special mention for all their effort,” said Dunwell. The employees spent

the day talking about careers in springmaking with students, showing the spring assemblies and discussing their various applications.

“SMI members and associate members should consider looking at the work their regional workforce development board is doing and getting involved in their activities,” Dunwell said. “As an industry, we all benefit greatly from seeing events like MiCareerQuest engage and excite young people about careers in manufacturing and springmaking.” z

As an industry, we all benefit greatly from seeing events like MiCareerQuest engage and excite young people about careers in manufacturing and springmaking.

Springs I Fall 2023 63

A Message from Gary

Gary McCoy

Looking Back and Looking Forward Growing up in Iowa I never considered the fact that springs surrounded me.

My father was an industrious blue-collar press operator at Meredith Printing, and he always enjoyed tinkering with things. If you navigated the stairs to our unfinished basement, you would see numerous clocks in various stages of repair. At the heart of these old clocks is a mainspring.

Jack McCoy has been gone nearly 20 years, but I still own a couple of his old clocks manufactured in Connecticut, a state which continues to be a hotbed of spring manufacturing. I am particularly fond of a shelf clock from the Waterbury Clock Company. The American clock industry, with scores of companies located in Connecticut’s Naugatuck Valley, used to produce millions of clocks, earning the region the nickname “Switzerland of America.”

Times changed, but the spring industry pivoted from clocks and hoop skirts to produce products for cellphones, toys and nuclear submarines, to name just a few.

As I have now been part of the spring industry since 2008, I see the unique role that springs play in our everyday lives. It makes me appreciate the SMI members who help make this possible. To help celebrate this, we have launched a new podcast called “Springs are Everywhere.” The podcast looks at the many uses of springs but also dives into the issues that spring manufacturers face, from recruiting and hiring new workers to automation and the coming role of artificial intelligence (AI). Listen to our inaugural edition and let me know what you think.

This issue toasts SMI’s 90th anniversary and the redesign of Springs.

We have created a cleaner look paired with a modernized style and fresh typography. In addition, you will see a new department called “Women in Springs.” Enjoy the article on Linda Froehlich, a member of our board and an entrepreneurial pioneer (see page 60). This department is also an extension of a new SMI community we are building to support the women in our industry.

In addition, we continue to see growth within a new community for the up-and-comers in our industry called “Avant-Garde.” Our goal is to support and mentor these future industry leaders. We will announce some new initiatives to help bring more of them to our annual meeting.

SMI is proud to celebrate its 90th anniversary. We look back to a glorious history but also look forward to the road ahead. Thank you for being a part of this great industry and for your various messages of support as I embark on this new adventure of leading your association.

Cheers!

Gary McCoy Executive Director

Springs I Fall 2023 65

Inside SMI SMI Heads to Coronado Island The beautiful island of Coronado will be the backdrop for the 2024 SMI annual meeting.

The meeting will take place April 6-9 at Loews Coronado Bay Resort, Coronado, California.

Perched on a 15-acre peninsula, Loews Coronado Bay Resort is surrounded by shimmering bay waters and the San Diego skyline. The resort features endless activities — from sailboat excursions and watersports to beaches, pool cabanas and pickleball courts. Yes, pickleball will return to the annual meeting after a successful inaugural event at the 2022 Scottsdale, Arizona annual meeting.

The annual meeting will mark the end of the presidency of Gene Huber Jr. as he hands the gavel to incoming president Don Jacobson III. You’ll want to be there as we thank Huber for his service and welcome Jacobson to his new role.

More details to come. Please mark your calendars for another exciting opportunity for the spring industry to gather for networking and education.

SMI Welcomes New Members Please join us in a warm welcome to SMI’s newest members.

EBSCO Spring Company Nick Dooley Tulsa, Oklahoma Integrity Spring & Fab LLC Houston, Texas Xavier De Leon Marvel Springs Inc. Paul Blandin de Chalain Flat Rock, North Carolina Ridge Nassau Ltd. Jean Jacques Jasmin Hawkesbury, Ontario

66 Fall 2023 I Springs

SMI Podcast to Launch Soon The first edition of “Springs Are Everywhere,” a new podcast from SMI, is scheduled for distribution in Sept. 2023. The podcast will focus on issues important to springmakers, such as workforce development, supply chain, automation, sales, marketing, leadership and more.

The program will be hosted by SMI executive director, Gary McCoy. “The podcast harkens me back to my early career working in radio news and sports,” said McCoy. “The program will include three short segments per episode and feature interviews with experts both within and outside the industry.”

McCoy says the podcast name is a deliberate attempt to show the outside world that springs are literally everywhere.

“From electronics to automobiles to the neighborhood playground, springs are often the hidden part that no one sees,” explained McCoy. “The truth is springs are highly engineered and a vital component that makes everything work properly.”

Stay tuned for the first episode and tune in using your favorite podcast outlet. Follow SMI on Instagram and LinkedIn for episode updates and information.

SMI Survey Schedule: An Opportunity to Benchmark with Your Peers SMI regularly surveys its members to help them understand how they are doing relative to others in the industry. Confidentiality is important when SMI conducts each survey. No company data is ever shared with SMI members or SMI itself.

Here’s the schedule of surveys for 2023 and into 2024.

Key Business Trends (regular and associate members)

Survey Sent

Responses Due

Results Sent

Third Quarter 2023

Oct. 5, 2023

Oct. 13, 2023

Oct. 14, 2023

Fourth Quarter 2023

Jan. 5, 2024

Jan. 15, 2024

Jan. 16, 2024

Salary (every other year — regular member contacts)

Survey Sent

Responses Due

Results Sent

2023

Oct. 1, 2023

Oct. 30, 2023

Nov. 30, 2023

Wages & Benefits (every other year — regular member contacts)

Survey Sent

Responses Due

Results Sent

2024

Aug. 6, 2024

Sept. 9, 2024

Sept. 20, 2024

Calendar z Key Events for the Global Spring Industry

2023 Spring Design Training Schedule

2024 April 6-9 SMI Annual Meeting Loews Coronado Bay Resort Coronado, California smihq.org April 15-19 wire and Tube Düsseldorf, Germany wire-tradefair.com tube-tradefair.com Oct. 2-4 SpringWorld Expo and Symposium Donald E. Stephens Convention Center Rosemont, Illinois casmi-springworld.org smihq.org

Class

Date

201 Compression Spring Design

Thursday, Oct. 19, 2023

202 Extension Spring Design

Thursday, Nov. 16, 2023

203 Torsion Spring Design

Thursday, Dec. 14, 2023

Send Us Your News SMI members receive priority placement for their product, company, personnel and events announcements in the magazine. Your news releases should be roughly 50 to 100 words and may be accompanied by color photos (high-resolution .JPEG photos at 300 dpi preferred).

Send to gaby@smihq.org.

Springs I Fall 2023 67

Podcast Picks

Gabriela Carrasco

HBR IdeaCast with Amy Bernstein Episode | How Generative AI Changes Productivity Length | 35 minutes I first used AI when I asked ChatGPT to help me choose a birthday gift for my 24-year-old brother.

He had started his first career job, so he could buy himself almost anything. This challenged me to get creative. ChatGPT suggested gifting him an experience. So, I bought tickets to “Drunk Shakespeare” in Chicago which he said was worth every penny and a shot of liquor.

In this issue, I will review the Harvard Business Review (HBR) IdeaCast’s “How Generative AI Changes Productivity,” hosted by HBR editor Amy Bernstein. The episode features Karim Lakhani, Harvard Business School professor and co-author of “Competing in the Age of AI.” Lakhani gives a brief history of generative AI, which began around seven years ago. Generative AI can access the entire internet’s knowledge and generate responses from prompts. It evolves through reinforced learning from human feedback, improving human-like responses.

AI can transform mundane tasks: analyzing spreadsheets, reviewing legal case studies and composing routine emails. It can enhance productivity by handling textual summaries, administrative jobs and even routine customer service. The potential for productivity gains is substantial but requires careful monitoring.

Addressing automation concerns, Lakhani says, “Humans with machines will replace humans without machines.” AI is like a airplane’s autopilot.

While an autopilot can do amazing things, it can still fall short sometimes and requires human oversight and direction. Generative AI can boost work quality. However, over-reliance can dull vigilance. Lakhani calls this “falling asleep at the wheel.”

Overall, generative AI promises more productivity in the workplace. It can streamline tasks that once took hours to a few seconds. Lakhani encourages leaders to learn and embrace AI, not just for their individual use but for their whole organization. Leaders will need to ask: If tasks that previously took two weeks now only take two hours, what do you do with the rest of the time?

Lakhani suggests the answer is not to reduce staff but to use the AI “superpower” to create more high-level work.

Recently, OpenAI, creator of ChatGPT, has announced an OpenAI for business is coming soon, so the journey continues. z

Springs I Fall 2023 69

Untangle Your Spring Problem stop WastIng tImE and man Hours!

D-Tangler 2000

rk, ma d an pe easy! y t t t Jus t’s tha i

American Made Over 25 Years Experience

IdEal For sEparatIng tanglEd: • Springs • Clips • Rings

• Stampings • Wire Forms • Small Parts

Easy to usE: Just drop your tangled

material into the input tube and out they come UNTANGLED!

Dispense Works Inc (815) 363-3524 | d-tangler.com info@d-tangler.com

70 Fall 2023 I Springs

Book Corner

Reviewed by Phil Sasso

The Seven Habits of Highly Effective People Few business self-help books withstand the sands of time.

Perhaps the most personally impactful one I’ve read is Stephen R. Covey's "The Seven Habits of Highly Effective People.” I just revisited the copy my brother, Richard, gave me more than 30 years ago, and I find it still relevant.

Originally published in August 1989, the book celebrates 35 years in print next summer. It’s gone through many marketing iterations, from “for teens” to “guided journal” to the sequel, “The 8th Habit.” But I still hold the original near and dear.

Covey's message is that personal effectiveness in life and work is grounded in character and principles. He researched American success literature from 1776 forward and discovered an interesting pivot. The first 150 years focused on character ethics like integrity, courage, justice and patience. After World War II, there was a shift in thinking to personality ethics, focusing more on attitudes, skills, techniques and outward actions.

While he says personality ethics skills are important, Covey believes they are secondary, not core.

Covey’s habits break into three sections: private victory, public victory and renewal.

The first three habits focus on personal discipline: be proactive, begin with the end in mind and put first things first. Our days can be twittered away on urgent but insignificant tasks. Covey encourages us to manage our time and energy purposefully.

The three public victory habits focus on building genuine, productive relationships: think win-win, seek first to understand, then to be understood and synergize. These help us to better cooperate, communicate and collaborate.

The seventh habit is about continued growth and renewal: sharpen the saw. Two lumberjacks compete, and the logger that wins is the one who stops to rest and sharpen his blade. Convey’s last habit is about renewal and life-work balance.

“This is the single most powerful investment we can ever make in life—investment in ourselves,

in the only instrument we have with which to deal with life and to contribute,” says Covey.

Covey grounds his teachings in real-world examples and provides a practical framework for integrating these habits into your life. He helps readers to navigate challenges, make principled decisions and take control of their lives.

If you’ve read the book before or not, I suggest you spend some time with “The Seven Habits.” Whether you check it out from your public library, read it on your Kindle or listen to the audiobook, I think you’ll find it time well spent personally and professionally. ❚

Have a favorite business book you would like to tell us about or review? Send you suggestions to Springs magazine editor Phil Sasso at phil.springs@sassomarketing.com.

Springs I Fall 2023

71

A Plan for the Future

Spring Manufacturers Institute 401(k) Retirement Program An exclusive SMI member-only benefit program Provide a superior retirement plan, spend less time on plan administration and save money Major advantages from three industry names you can count on:

In partnership with Fiduciary support from fiduciaryPATH 3(38) • Selects and monitors plan investments in accordance with the Investment Policy Statement (IPS) • Provides professional asset allocation solutions that are suited to each participant’s needs • Monitors fees to ensure they are reasonable • Advocates for plan sponsors by negotiating below-market investment costs whenever possible

Administrative support from 3(16) plan administrator Pentegra Retirement Services • Provides employee notices • Interprets and enforces Plan Document • Ensures IRS and Department of Labor compliance • Includes an ERISA attorney as part of the compliance team • Ensures flexibility in plan design • Signs and files the 5500 form as the plan administrator • Accepts nearly all responsibilities and powers of an ERISA fiduciary

Participant resources provided

by Empower Retirement • Online tutorials • Award-winning participant flyers • Quarterly statements • Electronic participant newsletters • Online requests for loans, distributions and hardships • Online investment fact sheets and prospectuses • Annual fee disclosure statements

Find out why several SMI members have already enrolled in the program to save money and relieve themselves of administrative burdens when you contact Liz Hickox at Core Financial Partners at 401-236-2350 or email liz@newportcfp.com Spring Manufacturers Institute, Core Financial Partners and Pentegra Retirement Services are not affiliated with GWFS Equities, Inc. or its parent company, Great-West Life & Annuity Insurance Company.

Securities offered and/or distributed by GWFS Equities, Inc., Member FINRA/SIPC. GWFS is an affiliate of Empower Retirement, LLC; Great-West Funds, Inc.; and registered investment advisers, Advised Assets Group, LLC and Personal Capital. This material is for informational purposes only and is not intended to provide investment, legal or tax recommendations or advice. ©2021 Empower Retirement, LLC. All rights reserved. GEN-FLY-WF-1017869-0421 RO1629942-0421 FOR PLAN SPONSOR OR FINANCIAL PROFESSIONAL USE ONLY. Unless otherwise noted: Not a Deposit | Not FDIC Insured | Not Bank Guaranteed | Funds May Lose Value | Not Insured by Any Federal Government Agency

New Products High-Speed CNC Coiler for Compression Springs The Simplex-Rapid MC 80 is a high-speed CNC coiling machine for the production of compression springs and is equipped with the latest generation multi-axis numerical control for the direct control of 12 axes with one-micron resolution. The MC 80 CNC coiler can handle wire diameters from 1.75 up to 8.00 mm.

The machine’s integrated motion control technology reduces the positioning errors of the axes to guarantee better accuracy. lt also optimizes synchronized movements and eliminates cycle idle time.

This machine is suitable for producing rightor left-handed compression springs with complex pitch/shape variations. In addition, the machine is equipped with a state-of-the-art video camera system for length and diameter control.

The Simplex-Rapid coiling machine is also equipped with a programmable automatic shut-off function to make the machine compliant with new sustainability requirements.

For more information, contact NIMSCO LLC, the North American distributor for Simplex-Rapid, at nimsco.com or at simplexrapid.it.

Simplex-Rapid MC 80 CNC spring coiling machine

Send us Your News SMI members get priority placement of their product news.

News releases should be roughly 50 to 100 words and may be accompanied by color photos (HiRes .JPEG at 300 dpi preferred).

Send to gaby@smihq.org.

Springs I Fall 2023 73

New Products

New FUL 126 Spring Coiler with “Speed Mode” WAFIOS introduced the FUL 126, expanding its FUL series for mediumrange spring production. The FUL series creates compression and tension spring coils spanning 0.12 mm to 30 mm. Positioned as a successor to the FSE 93, the FUL 126 enhances possibilities for manufacturing left and right coiled compression springs, with a focus on the automotive sector, including chassis and technical springs.

The working range now extends to 12 mm O.D. with 2000 N/mm² hightensile wires, complemented by a 25% faster feed speed at 100 m/min.

This high-performance coiler targets maximum output.

Noteworthy features of the new spring coiler include adaptable right/ left coiling, influenced by the PTP coiling finger, ideal for technical/chassis springs with pre-stressing or inner ends. The FUL 126 autonomously adjusts axle parameters based on spring specifications. The coiler optimizes feed speed according to wire diameter, coiling ratio and tensile strength, enhancing output up to 13%.

Additionally, the WAFIOS iQspring2FUL feature enables automated replication of spring geometry from a reference spring to WPS 3.2 EasyWay. This innovation significantly reduces spring program creation time and works universally across spring coilers.

For more information visit wafios.us. z

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Shape it as you please.

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In the hands of skilled craftsmen, our steel becomes the parts, components and products that make the world turn. For over 65 years, fabricators and manufacturers big and small have trusted Admiral Steel to help them leave their mark on the world. For any size order from 10 lbs. to 10,000, you get first-class quality, on-time delivery, and personalized service from Admiral. Contact us for a quote today! ™

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74 Fall 2023 I Springs

WAFIOS FUL 126 CNC spring coiling machine

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naspringtool.com 860-583-1693

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Mapes: quality that’s never out of tune.

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The high-performance wire for your demanding spring jobs.

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Advertisers’ Index A & D Trading I 440-563-5227........................................................18

Simplex Rapid I 563-391-0400.......................................................52

Admiral Steel I 800-323-7055.........................................................74

SMI I 847-450-6846...............................Inside Front Cover, 27, 72

Alloy Wire International I 866-482-5569 ��������������������������������������11

Starrett I 888-674-7443................................................................... 59

Anchor Abrasives I 708-444-4300...................................................9

Tool King I 847-537-2881.................................................................27

BB Spring Technology I +39-031-536584 ��������������������������������� 68

United Wire I 800-840-9481.......................................................... 50

CASMI I www.casmi-springworld.com........................................ 28

WAFIOS I 203-481-5555.....................................................................6

Diamond Wire I 800-424-0500.....................................................27

Zapp Precision Strip I 203-386-0038............................................ 14

Dispense Works I 815-363-3524....................................................70 FENN/Torin I 860-259-6600...........................................................24 Forming Systems Inc. I 877-594-4300........................Back Cover Gibbs Interwire I 800-800-4422.................. 1, Inside Back Cover Gibraltar I 847-383-5442................................................................. 64 Industrial Steel & Wire I 800-767-0408 �����������������������������������������3 Larson Systems I 763-780-2131......................................................70 Mapes Piano String Co I 423-543-3195.......................................75 NIMSCO I 563-391-0400.................................................................75 North American Spring Tool I 860-583-1693 ����������������������������74

Proto Manufacturing I 800-965-8378 ������������������������������ 27 Radcliff Wire I 860-583-1305..........................................................23 RK Trading I 847-640-9371................................................................5

Advertise in Springs magazine!

Promote your products and services.

Build your brand.

Increase awareness.

Generate leads.

Grow your sales.

Engage with leading spring manufacturing industry influencers and decision-makers from across North America.

Contact Gary McCoy at gary@smihq.org or 847-450-6240 for details.

Springs I Fall 2023 75

Alex Altstatt y Western Spring Mfg

Snapshot Name: Alex Altstatt

The one thing I can’t stand is: Tables that

Company name and city: Western Spring Mfg.

wobble at restaurants. It reflects poorly on the management and usually the food.

Hugo, Minnesota.

A brief history of your company: A multigenerational family-owned and operated company that has evolved from a blacksmith shop to a precision spring and wireform manufacturer.

Job title: Operations Manager.

What I like most about being a springmaker: That there are no rules, just best practices.

Especially true in the wireforming department.

As long as the parts are produced in an efficient manner while maintaining consistency to specifications, part after part, the customer is going to be satisfied.

Birthplace: St. Paul, Minnesota.

Family (spouse, children, pets, etc.): Wife, Nicole,

My most outstanding qualities are: Persistence. Us Altstatt’s keep showing up to work. That is likely a key to our success.

I knew I was an “adult” when: A life insurance policy was underwritten.

If I weren’t working at (Western Spring Mfg.), I would like to: Be a machinery rigger. Large trucks, forklifts, cranes and dicey situations would keep me on my toes.

The most difficult business decision I ever had to make was: Joining the family business post-college and post-internship.

I wonder what would have happened if: I had never joined the family business.

daughter, Ava (6), and son, Oliver (4), along with our small Yorkie Bo and a bunch of chickens.

Role models: All the Altstatt’s that came before me that have worked at the spring shop.

Favorite food: A nice cut of ribeye steak with a side of mushrooms, onions and mashed potatoes.

If I’m lucky there will be leftovers for the next day’s lunch.

Favorite quote: “Everybody has a plan until they get punched in the mouth.” — Mike Tyson

Hobbies: Crewing on a 7-man A-scow sailboat, bass fishing league, golf, men’s hockey league and ice fishing.

suppliers to email wire certs rather than only providing paper copies (though I’ll probably never get credit for this!).

Favorite places: There’s no place like home, but northern Minnesota vacations in the summer and Florida in the winter are tough to beat.

But people will probably remember me for: Doing what I love and never “working” a day in my life.

I would like to be remembered in the spring industry for: Convincing the wire and strip

What podcast and/or music are you currently listening to: Podcasts like Made in America, How I Built This and Garage Logic.

What is on your bucket list: Alaska fishing trip with my fishing buddies. We hope to make that happen soon. We always seem to make great memories with our outings.

Aside from necessities, what is one thing you could not go without: My pocket knife. I use it everyday; I hate it when I forget it.

Best times of my life: There is no time like the present, tomorrow is not a guarantee.

A really great evening for me is: A hot summer night relaxing with the family right before sunset.

The “golden hour” is the best.

76 Fall 2023 I Springs

Pictured (l-to-r): Alex, Ava, Oliver and Nicole Altstatt.