Torsion Spring Design
Introduction
Springs used to apply torque or store rotational energy are generally called torsion or double
torsion springs. Torque by definition is a force that produces rotation. A torsion spring exerts a
force (torque) in a circular arc, and the arms rotate about the central axis. The stress is in
bending, not in torsion. It is customary to specify torque with deflection or with the arms at a
definite position.
Torsion bar
The torsion bar is the simplest form or torsion beam. It comprises a solid or hollow bar which is
stressed in torsion within its elastic limit.
Nomenclature
R = lever radius (m)
D= bar outside diameter (m)
d= bar inside diameter (m)
L = bar length (m)
ka = Stiffness (Nm) G = Modulus of Rigidity (N/mm2)(m)
τ = Allowable shear stress
θ = Deflection (radians)
Solid Bar
Deflection θ = 32PR2 L /( π GD 4 )
Stiffness k a= πG D4 /(32R 2 L)
Maximum Load Pmax = π D3 τ /(16 R)
Hollow Bar
Deflection θ = 32PR2 L /( π GD 4 )
Stiffness k a= πG (D 4 -d 4) /(32R 2 L)
Maximum Load Pmax = π(D 4 -d 4) τ /(D 16 R)
Torsion Spring
A typical torsion helical spring is shown below. There are a wide variety of coil end configurations
to suit different applications and a torsion spring is usually positioned on a shaft. The coils are
usually close wound as are tension springs but they generally do not have any initial tension
unlike tension springs.
The primary stress induced in torsion spring is a bending stress in the wire . This is not the case
for the tension and compression helical springs for which the primary stress is a torsional (shear)
stress. During forming residual stresses are built up in the winding process. These residual
stresses are in the same direction but of opposite sign to the working stresses resulting when the
spring is loaded causing the coils to tighten. Torsion springs are stronger as a result and they are
often designed to work at, or above the yield strength.
Nomenclature
C = Spring Index D/d
d = wire diameter (m)
D = Spring diameter (m)
Di = Spring inside diameter (m)
Dil = Spring inside diameter (loaded ) (m)
E = Young's Modulus (N/m2)
F = applied Force (N)
G = Modulus of Rigidity (N/m2)(m)
ka = Angular spring rate (stiffness) M /θ (Nm /radian)
L = length (m)
M = Moment (Torque) = RF (Nm)
n = Number of active coils
y = distance from neutral axis to outer fibre of wire (m)
τ = Allowable shear stress (N/m 2
)
θ = Deflection (radians)
σ = Bending stress σ(N/m ) 2
Note: metres (m) have been shown as the units of length in all of the variables above for
consistency. In most practical calculations milli-metres will be more convenient.
Torsion Spring Formulae
The spring stress concentration factors Ki =
The maximum bending stress is at the inner fibre of the coil and equals
The angular spring rate ka =
Torsion springs are often used over shafts. It is important that the spring inside diameter, when
fully loaded is no t equal to, or less than the shaft diameter. If this happens the spring will fail.
The inside diameter of the loaded tension spring is
