How can non-linear spring rates be detected and resolved in Crest-to-Crest wave spring systems?

Non-linearity in Crest-to-Crest springs typically occurs at the beginning of the stroke due to 'flatness' issues and at the end of the stroke as the spring approaches solid height. If the load-deflection curve shows an early 'lag,' it indicates that not all wave peaks are contacting the mating surfaces simultaneously. This is often resolved by tightening the parallelism tolerances on the spring ends. If the rate spikes prematurely, it suggests the waves are 'nesting' or shifting radially and contacting the bore/shaft. Using a shim or a 'level-end' design, where the first and last waves are flat, provides more uniform contact.