Wire With Greatest Bending Fatigue Resistance

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Discussion Overview

The discussion centers on selecting an appropriate wire material to enhance flexibility in a joint design. Participants explore options for materials that can withstand repeated flexing without breaking, while also considering the need for the joint to maintain a set position without springing back. The conversation includes suggestions for alternative designs to achieve the desired flexibility.

Discussion Character

  • Exploratory
  • Technical explanation
  • Conceptual clarification
  • Debate/contested

Main Points Raised

  • Don seeks a flexible wire material for a joint that may be flexed 2-3 times per day and is concerned about the material's durability.
  • One participant suggests using a specific type of cable from robotic wafer handling systems, though they note it may be overkill for the application.
  • Another participant questions whether the material needs to act as a spring or simply be durable under flexing, proposing phosphor bronze as a reliable option.
  • Don clarifies that the joint should not spring back and expresses concern about whether phosphor bronze can withstand thousands of flexes without snapping.
  • A participant confirms that phosphor bronze is versatile and durable but expresses uncertainty about its ability to hold a new shape after being flexed.
  • One participant suggests considering tight-fitting U-joints as an alternative to a single piece of flexible metal for better functionality.
  • Don agrees that a tight-fitting joint may be a better solution.
  • A later reply emphasizes the importance of including an adjustment mechanism to account for wear over time.

Areas of Agreement / Disagreement

Participants generally agree on the need for a durable material that can withstand repeated flexing, but there is no consensus on the best specific material or design approach. Some participants propose different solutions, indicating that multiple competing views remain.

Contextual Notes

Participants express uncertainty regarding the specific performance characteristics of phosphor bronze in this application, particularly its ability to hold a new shape after flexing. There are also considerations about the appropriateness of alternative designs, such as U-joints, which remain unresolved.

Who May Find This Useful

This discussion may be useful for individuals involved in mechanical design, robotics, or materials science, particularly those interested in joint flexibility and material durability in engineering applications.

itsdonny
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I need to add flexibility to this joint (where the arrow is pointing) and I was thinking about using a method I saw on this flexible clamp. I ripped it apart and it looks like they used copper wire as the flex material. What would be the best wire to use? I'm worried that perhaps it could only be flexed so many times before breaking. The design I'm making won't require continual flexing but some users may flex the joint 2-3 times per day at the most.

Also I'm open to other ideas to add flexibility to this joint if you have any ideas.

Thanks!
Don

http://laphotopro.com/public/hinge-flex.jpg
http://laphotopro.com/public/flex-wire-05-sm.jpg
http://laphotopro.com/public/flex-wire-04-sm.jpg
http://laphotopro.com/public/flex-wire-03-sm.jpg
http://laphotopro.com/public/flex-wire-02-sm.jpg
http://laphotopro.com/public/flex-wire-01-sm.jpg
 
Last edited by a moderator:
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Do you need something that acts as a spring, or simply is durable under flexation? That might limit the options. In either case, though, phosphor bronze is always a reliable choice.
 
Thanks guys. I don't want it to spring back. I want the user to be able to adjust it to the position of their liking and have it stay there. I just want to make sure I'm using a material that can be flexed thousands of times and not snap. Phosphor bronze will do this?
 
itsdonny said:
I just want to make sure I'm using a material that can be flexed thousands of times and not snap. Phosphor bronze will do this?

Absolutely, but I'm not sure about it holding a new shape. It's pretty versatile, though, so I expect that some version of it will do so. It's used in everything from the springs in the pin cells of locks to dental appliances such as braces. Ship propellers are often made from it as well, since it has terrific corrosion resistance.

edit: Something else just came to mind, but it probably won't be appropriate for you. I had a wee flashback to this snaky thing that let's me use my screwdriver around corners. Would it be to your advantage to use one or more tight-fitting U-joints rather than a single piece of flex metal? It would be something like the armatures that model-makers use for the positioning of characters in stop-motion animation films.
 
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I think you're right Danger. A tight fitting joint may be the best way.

Thanks
 
You're more than welcome. I hope that it works for you. Remember to design in some sort of adjustment screw or other system to compensate for loosening due to wear.
Please post your results when you get done; I'm interested to see how it turns out.
 

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