Changing the spring wire diameter

Spring stiffness (k) depends on wire diameter (d) to the fourth power:

k ∝ d⁴

To calculate the reduction in stiffness when changing from 2 mm to 1.6 mm, use the ratio:

Reduction in stiffness = ( (1.6 / 2) )⁴

Calculation:

(1.6 / 2) = 0.8 (0.8)⁴ = 0.4096

Result:

The spring's stiffness will be 40.96% of the original, a reduction of approximately 59.04%.

Practical interpretation:

• The spring will be significantly more flexible.
• The force needed to compress it by the same distance will be 59% lower than with 2 mm wire.