Actuation performance of machined helical springs from NiTi shape memory alloy

Machined helical springs were designed and fabricated from NiTi shape memory alloy tube stock by cutting helical slots to make the coils, which provided them with high design flexibility and actuation potential. The springs were then subjected to isothermal tensile testing at temperatures of 20°C and 80°C, the experimental data showed that they could generate more than 50% actuation stroke at the applied force of 300 N. A material model was introduced to describe the thermally-induced actuation behavior of the machined NiTi spring. Finite element simulation of the springs was carried out to investigate the effects of geometries and applied loads on the actuation performance. With increasing applied load, the actuation stroke and transformation temperature increased as well, indicating more actuation potential at high loads. The actuation stroke was positively correlated to the outer diameter and the cross-sectional aspect ratio, negatively correlated to the cross-sectional area, and independent of the coil pitch. A variable-sweep wing actuated by two antagonistic machined springs was designed and numerically analyzed, the actuator could generate a steady cyclic motion up to 40 mm and allowed the swept-back angle of the wings to be continuously varied from zero to 90 degrees. [Display omitted] •Machined NiTi springs show same actuation stroke but 6 times force as wire-wound ones.•User-defined material model well describes thermally-induced actuation at varying stress.•Spring geometries and applied load show a strong impact on actuation performance.•Machined spring can provide large continuous swept-back deformations of the wing.