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A Belleville spring washer should be designed so that it can be compressed flat by accidental overloading, without setting. This can be accomplished either by using a stress so low that the spring will not set or by forming the spring higher than the design height and removing set by compressing flat or beyond flat (see Table 6.21). The table values should be reduced if the washers are plated or used at elevated temperatures. For fatigue applications it is necessary to consider the tensile stresses at the points marked ST1 and ST2 in Fig. 6.27. The higher value of the two can occur at either

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the ID or the OD, depending on the proportions of the spring. Therefore, it is necessary to compute both values. Fatigue life depends on the stress range as well as the maximum stress value. Figure 6.32 predicts the endurance limits based on either ST1 or ST2, whichever is higher. Fatigue life is adversely affected by surface imperfections and edge fractures and can be improved by shot peening. Since the deflection in a single Belleville washer is relatively small, it is often necessary to combine a number of washers. Such a combination is called a stack. The deflection of a series stack (Fig. 6.33) is equal to the number of washers times the deflection of one washer, and the load of the stack is equal to that of one washer. The load of a parallel stack is equal to the load of one washer times the number of washers, and the deflection of the stack is that of one washer.

That top of a call stack is from the nastiest crash I encountered during the development of Dapple. I ll talk more about this particular crash in the Reproducing Rare Crashes section.

FIGURE 6.32 Modified Goodman diagram for Belleville washers; for carbon and alloy steels at 47 to 49 Rc with set removed, but not shot-peened. (Associated Spring, Barnes Group Inc.)

TABLE 1-1

FIGURE 6.33 Stacks of Belleville washers. (Associated Spring, Barnes Group Inc.)

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Because of production variations in washer parameters, both the foregoing statements carry cautionary notes. In the series stack, springs of the constant-load type (h/t = 1.41) may actually have a negative rate in some portion of their deflection range. When such a series stack is deflected, some washers will snap through, producing jumps in the load-deflection curve. To avoid this problem, the h/t ratio in a series stack design should not exceed 1.3. In the parallel stack, friction between the washers causes a hysteresis loop in the load-deflection curve (Fig. 6.34). The width of the loop increases with each washer added to the stack but may be reduced by adding lubrication as the washers burnish each other during use. Stacked washers normally require guide pins or sleeves to keep them in proper alignment. These guides should be hardened steel at HRC 48 minimum hardness. Clearance between the washer and the guide pin or sleeve should be about 1.5 percent of the appropriate diameter.

If you re having problems with symbolicatecrash or if you want to go at it old-school, you can try your hand with atos. This is the command that symbolicatecrash uses at its heart. atos lets you find a symbol name for a given memory address. To use atos, you need to put an app and its corresponding dSYM in the same directory. You ll want to copy the app and dSYM file that you archived when you sent the build to your testers into the same directory as your crash log file. Copy just the memory addresses from the crash log into a new text file, and place that file in the same

BASIC STAMP I/O INSTRUCTIONS BASIC STAMP 2 (BS2)

6.7.3 Tolerances Load tolerances should be specified at test height. For carbon-steel washers with h/t < 0.25, use load tolerance of 15 percent. For washers with h/t > 0.25, use 10 percent. The recommended load tolerance for stainless steel and nonferrous washers is 15 percent. See Table 6.20 for outside- and inside-diameter tolerances.

FIGURE 6.34 Hysteresis in stacked Belleville washers. (Associated Spring, Barnes Group Inc.)

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