How to bend lock washers like a master in 3 easy steps

Lock washers are essential components in various applications, ensuring the integrity of bolted connections. However, bending lock washers requires precision and the right techniques to avoid damaging them. This comprehensive guide will provide you with step-by-step instructions on how to bend lock washers effectively and efficiently.

Understanding Lock Washers

Lock washers, also known as split washers or spring washers, are thin, split rings made from hardened steel or stainless steel. They are placed under the head of a bolt or nut to prevent loosening due to vibration or other forces.

Types of Lock Washers

There are various types of lock washers, including:

• Internal Tooth Lock Washers: Have teeth on the inside diameter that bite into the surface of the bolt or nut.
• External Tooth Lock Washers: Have teeth on the outside diameter that grip the surface of the washer or nut.
• Wave Lock Washers: Have a wavy shape that creates a spring-like action, resisting loosening.

Tools Required

To bend lock washers, you will need the following tools:

• Lock washer
• Needle-nose pliers
• Flat-head screwdriver or punch

Safety Precautions

Before bending lock washers, it is crucial to take the following safety precautions:

• Wear safety glasses to protect your eyes from flying metal fragments.
• Use gloves to prevent cuts or abrasions.
• Secure the workpiece firmly in a vise or clamp to prevent it from moving.

Step-by-Step Bending Instructions

1. Choose the Correct Lock Washer

Select the correct lock washer size for the bolt or nut you are using. The lock washer should fit snugly around the bolt or nut.

2. Position the Lock Washer

Place the lock washer under the head of the bolt or nut. Ensure that the teeth or wavy surface faces the workpiece.

3. Grip the Lock Washer

Using needle-nose pliers, grip the two ends of the lock washer firmly.

4. Bend the Lock Washer

Gently bend the lock washer into a slight arc. Do not over-bend, as this can damage the washer.

5. Flatten the Lock Washer

Use a flat-head screwdriver or punch to flatten the bent portion of the lock washer against the workpiece.

6. Rotate the Lock Washer

Rotate the lock washer 180 degrees and repeat steps 4 and 5. This ensures that both ends of the lock washer are bent evenly.

7. Check the Lock Washer

Inspect the bent lock washer to ensure that it has the desired curvature and fits securely under the head of the bolt or nut.

Common Bending Mistakes

Avoid the following common mistakes when bending lock washers:

• Over-bending: This can damage the washer and reduce its effectiveness.
• Bending at an angle: The lock washer should be bent in a perpendicular direction to the workpiece.
• Using excessive force: This can cause the lock washer to break or lose its elasticity.

Applications of Lock Washers

Lock washers are widely used in various industries, including:

• Automotive
• Construction
• Manufacturing
• Electronics
• Aerospace

Wrapping Up

Bending lock washers is a simple but crucial task to ensure secure bolted connections. By following the step-by-step instructions and safety precautions outlined in this guide, you can effectively bend lock washers and prevent loosening due to vibration or other forces.

Popular Questions

Q: What is the purpose of bending lock washers?
A: Bending lock washers creates tension and friction, preventing them from loosening under load or vibration.

Q: Can I reuse bent lock washers?
A: It is not recommended to reuse bent lock washers as they may have lost their elasticity and effectiveness.

Q: What is the difference between internal and external tooth lock washers?
A: Internal tooth lock washers grip the bolt or nut, while external tooth lock washers grip the surface of the workpiece.

Q: How do I know if a lock washer is bent correctly?
A: The lock washer should have a slight curvature and fit securely under the head of the bolt or nut.

Q: Can I use pliers to bend lock washers?
A: Yes, needle-nose pliers can be used to bend lock washers gently and effectively.