What is the length of wire needed to create this spring?
So I model the spring:
I then create a helix that runs through it entirely. Figure it intersects any quadrant on the starting-bottom circular face and it will intersect the same quadrant on the finishing-top circular face; thing left to left, top to top, center to center. Measure that helix and you get:
Arc Length = 28.11"
Another method might be to evaluate the volume of the modeled spring and reverse-solve for the length:
0.33720901=π(.0625)²h; h=0.33720901/(π(.0625)²) = 27.48"
Another method might be:
where π = 3.14..., c= number of coils/turns, D = outer diameter (1") and d = wire diameter (.125") giving you:
10π(.875) = 27.49"
It's interesting that the last two numbers differ, I imagine because of rounding error. What I don't understand is why does my perfectly-aligning helix not measure the same? It must be fundamental I don't understand about Arc-Length
Is there a method, maybe using surfaces or sheet-metal, to flatten this out to measure? The math gives me a different number. I could imagine a scenario where I'm making a million springs and end up a few hundred feet short of wire based on SolidWorks' measurement.