Torsion Springs
General Data
“Torsion springs, whose ends are rotated in angular deflection,
offer resistance to externally applied torque. The wite itsel is
‘subjected to bending stresses rather than torsional stresses, as
right be expected from the name. Spring ofthis type ae usualy
close wound, reduce in coi diameter, and increase in boy length as
they ate deflected, The designer must consider the eflects of
friction and arm deflection on the torque
Special types of torsion springs include double torsion springs
and springs having a space between the cols to minimize friction.
Double torsion springs consist of one right-hand and one left-hand
‘coil section connected together, and working in parallel. The
sections are designed separately with the total torque exerted
beeing the sum of the two,
Type of Ends
‘The type of ends on torsion springs should be carefully
considered. While there is a good deal of flexibility in specifying
special ends and end forming, the cost may be increased and a tool
charge incurred. The designer should check nominal free angle
tolerances in Table 2, this section, with respect to application
requirements,
Specifications
In addition to supplying the information requested on the
torsion spring specification form on page 26, itis important that
drawing be provided detailing the end conigrations.
Installation
‘The type of ends and installation affect spring load and
4eflection as shown in Figure 1. All torsion springs have three or
‘more points of contact with atleast two at the ends and one at the
arbor. For clarity, the designer should specify the position of the
contact points on the spring and their position relative to one
another.
Figure 1
Fixed pont
or
Point (A) rotates in an are about the center
ofthe shat
Design Formulas
The basic formulas for torque or moment (M) and bending
stress (S) used in designing torsion springs are shawn below.
In the formulas the constants 10.8 and 6.6, while not strictly
theoretical, give results closer to the actual values obtained.
D = Mean coil diameter, in. (mm)
4 = Diameter of round wire, in. (nim)
Ny = Number of cols
E = Modulus of elasticity, psi (MPa)
T = Deflection, number of turns or revolutions of spring
S = Bending stress, psi (MPa)
‘M = Moment or torque, Ibsin. (N
b = Width, in, (mm)
t= Thickness, in. (mm)
(SMIRound Wire
Wound on Flat
aT _ Ebr
era @ M- oR
32M
@ = ® s=it
Rectangular Wire
a) M
(a) s= 58
Wound on Edge
Ew
66ND
eM
wb?
‘The basic design approach is first to calculate the wire
ameter () in formula 2 using the specified maximum torque (M)
and a trial value of maximum design stress (S), which for all
‘materials is assumed (o be 75 percent of minimum tensile strength
given on pages 44 to 46. Ifthe value of S forthe calculated d does
‘ot adequately agree with the trial value ofS, formula 2 should be
used again to calculate an adjusted valve of d, this time using the S
for the first calculated d rather than the original trial value of S.
When a standard wire diameter just larger than the adjusted
Value of dis selected, calculate the design stress again in formula 2
for the adjusted value of d and compare it with the maximum
allowable design stress. In planning this design, the engineer should
carefully consider the pre-loading conditions and the change in
spring dimensions with deflection, so that adequate clearance is
provided. Springs should be designed to deflect in the direction of
winding. This causes the diameter to decrease and length to
Table 1.
‘TORSION SPRINGS
iameter Tolerances, * in. (mm)
Wire
Dia, :
A Spring Index. D/d
iom| 4 [6 Ts | 10 [2 16
‘0.15 | 0.002 | 0.002 | 0.002 | 0.002 | 0.003 0.004
0.38 | (0.05) | (0.059 | c.05) | (0.05) } c.08 @.10)
16.023 | 0.002 | 0.002 | 0.002 | 0.003 | 0.004 0.006
0338) | (6.05) | (0.05) | (.05) | (.08 | coo 0.15)
1.035 | 0.002 | 0.002 | 0.003 | 0.008 | 0.006 0.009
0389 | (0.05) | (0.05) | c.08) | (10 } (0.5) 023)
16.051 | 0.002 | 0.003 | 0.005 | 0.007 | 0.008 o.o12
1.30) | 05) | (.08) | (13) | @.18) | 20) (030)
10.4076 | 0.003 | 0.009 | 0.007 | 0.009 | 0.012 0018
289 | 08 | @.3) | 8 | 23 | 20 (0.6)
0.14 | 0.004 | 0.007 | o.010 | 0.013 | 0018 0.028
290 | (o.0 | (0.8) | 25) | 39) | (046) 7)
0.472 | 0.008 | o.010 | 0.013 | 0.020 | 0.027 0.042
437 | 19 | 025 | 29 | os» | os aon
0250 | 0.008 | 0.014 | 0.022 | 0.030 | 0.040 0.060
635) | 020 | 0.36) | 056) | 0.76 | 4.02) as
increase. The LD. in the deflected position (LD..) can be estimated
ia
Ni
>(g4)
‘The body length the deflected poson (is
L=dQ+1+T)
‘The longer and mor extensively formed the spring arms, the
higher the cot for ting and secondary operations Tere,
relatively short, straight arms should be specified wherever poss:
be.
1D,
Table 2.
‘TORSION SPRINGS
Free Angle Tolerances, + degrees
Namber Spring Index, D/d
‘of Coils
wm | 4 |6| 8 | 10 | a2 | a4 | 16 | 18 | 20
1 |2 | 3] 35[4 | 45] 5 | ss] ss] 6
2 |4a|sle]7]|s | as| 9 | 95] 10
3 | ss|7| 8 | ss]105/u |a2 |as | a
4 | 7 | [ao faz fas |as fas }aes} az
s | |iofi2 }aa |a6 |1s |20 | 205] 21
6 | 95}iz|ias}ie |19 | 205] 21 | 225] 24
a [a2 |as|is |20s| 23 | 25 | 27 | 28 | 29
10 |aa [19] 21 | 28 | 27 | 20 |sis}s2s| 34
1s }20 |25|28 |s |e | 36 | 3s [ao | 42
2 [2 |so|ae [sr fa fas far [ao | ot
2 | |as|40 faa [as |52 | 56 |oo | 63
30 |a2 |as|4e |so |ss | 60 | 6s |os | 70
so_|4s_|ss|6s_|7o [77 | ss [oo |95 | 100
|\SMI\:Design Example
Design a torsion spring to counterbalance a trapdoor. The
oor weighs 20 Ib (9.07 kg) and its widths 18 in. (457-2 mm) The
oor should remain closed from its own weight, but the spring
Should hold t open inthe upward direction aginst stop 110°from
the dosed positon, The material is oiltempered wire. The spring
rust work over a 1.10 in (27.94 mm) diameter shaft
Wire Diameter
‘The torque exerted by the door at the closed position is the
‘weight ofthe door times the distance from the center of gravity to
the hinge: 201, x 9 in, ~ 180 b. in. (20.300 Nem). The spring
should bea litle weaker so that the door willatay closed, so assume
that the spring will carry 90 percent of the weight. Then My =
.90(180) = 162 Ib.+in. (18,300 Nemm) If a torque of My = 10
Ibein (1190 Nem) is assumed a the open positon ofthe dor,
the torque should increase 152 bon. (17,200 Nemm) through the
1 deflection.
The frst step i to determine the wire diameter which will
carry this load. Assuming a minimum tensile strength of 270,000
psi (1862 MPa) inthe mid-range for music wire the tial value of
design stress is Sp = .75(270,000) = 200,000 psi (1379 MPa)
Transpose stress formula 2 to solve for wie siz.
=
fa _ 3a
Vass” Vtzongon)~ 9212 (213 mm)
Seventy-five percent of minimum tensile strength for this
wire diameter is 0.75(190,000) = 142,000 psi (979 MPa). Since
this figure is not close enough to 200,000 psi (1379 MPa), wire
diameter must be recalculated in formula 2. Therefore, repeat the
above calculation with $ = 142,000 psi (979 MPa).
s/s)
'7(142,000)
0.226 in, (5.74 mm)
In this case, proceed using .225 in. (5.72 mm)
‘The maximum allowable stress for d = 0.225 in. (5.72 mm) is
= 0.75(188,000) = 141,000 psi (972 MPa). Since the tral stress
‘of 142,000 (979 MPa) is very close to this figure, the design may
safely be accepted
Number of Coils
‘Transpose the torque formula 1 to solve for number of coils
(N) using the angular deflection T = 110°/360° = 0.308. Choose a
diameter which will provide clearance over the 1.10 in. (27.94 mm)
shaft. Try a mean diameter of 1.5 in. (38.1 mm) to allow for wire
diameter, 10 percent operating clearance, and diameter reduction
‘due to deflection,
yy, = BAT_ _ G0 x 108\0.225)40.306)
“* ZoaDM~ — 10.801.5X162 = 10)
If the design required an exact number of coils such as when
the ends must have a particular relationship, formula 1 should be
transposed to solve for D using the required number of coils
‘between 9 and 10. The final step is to check the diameter clearance
‘over the shaft and the axial length ofthe spring with respect to the
space available, both in the fully deflected position.
Clearance
‘The LD. and body length in the deflected position from free
6 coils
96.
12785 + 0326
1.233 in, (31.92 mm)
L, = dQ + 1+ T) = 2259.6 + 1 + 0.306)
2.458 in. (62.44 mm)
‘These compare favorably to the design criteria.
|) SMI: