How do you calculate the required bore clearance for a wave spring to prevent binding during compression?

During compression, the outer diameter ($OD$) of a wave spring expands as the wave peaks are flattened. The maximum $OD$ at the fully compressed height can be estimated by $OD_{max} = ext{Mean Diameter} + ext{Radial Wall} + ext{Expansion Factor}$. A practical rule of thumb is $Clearance_{min} = 0.02 imes ext{Deflection} imes ext{Number of Waves}$. If the housing bore is too tight, the spring will bind against the wall, causing a dramatic and uncontrolled increase in spring rate and potential surface galling. Engineers must specify the bore diameter such that Bore $> OD_{max} + ext{Tolerance Stack-up}$.