Answer
The solid height $H_s$ of a nested wave spring is not simply the sum of material thicknesses. It is calculated as $H_s = (n \cdot t) + (n-1) \cdot \delta$, where $n$ is the number of turns, $t$ is the thickness, and $\delta$ is the nesting gap factor, though in a perfectly nested spring, $\delta$ approaches zero. The actual height must also account for the radial expansion of the material during compression. As the spring is compressed toward solid, the mean diameter $D_m$ increases according to the formula $\Delta D = 0.02 \cdot (f^2 / D_m)$, where $f$ is the deflection. If the bore clearance is insufficient to accommodate $\Delta D$, the spring will bind, leading to an unpredictable non-linear spring rate and potential catastrophic failure of the assembly.
