Torsion spring technology calculation

How to calculate the force of a lever engaged with a torsion spring

Torque (T) = r* F

T=r*F
F = force (N)
r = Displacement distance (mm)
100
T = Torque (Nmm)

F = 50 N
Maximum force specification to
r= 100 mm T = 100 *50
operate the lever at this point is
50N T= ?? T = 5000 Nmm

The spring should be designed with the spring torque of 5000 Nmm
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How to identify LH and RH winding spring?
Hand or winding direction of springs

Anti Clockwise direction Clockwise direction

Why the winding direction of the torsion spring is important?

The winding direction of the torsion spring is important for the effective
utilisation and life of the spring.
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What is the correct direction for force application on the torsion spring?

Correct force application direction Wrong force application direction

The winding direction should be decided based on the force application.

Deflecting the spring in an unwinding direction causes high stress and premature failure of the
spring.
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How the torsion spring functions?

Functional arm

Spring
Body Deflected or loaded position

Stationary arm

Arm support

When a force applied on the functional arm , the functional arm rotates and the
energy is stored on the arm. When the load is withdrawn the arm returns to its
equilibrium position or idle position.
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Design position of the torsion spring with respect to pin/Rivet?

Wrong Position Correct

Position
Due to preload the spring body moves from its axis and gets supported by the
rivet ,rod or housing which is located at its center. This is very important point if the spring
geometry is wrongly located during design leads to problem of space and collision with near by
aggregates.
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What is Spring index or Spring rate?

The amount of force required to deflect the spring is called spring rate or spring index
Spring Index = Spring torque ( Nmm) / operating angle (deg)

Example calculation:
Spring torque = 5000 Nmm
Operating angle = 50 deg
Spring Index = 5000/ 50 = 100 Nmm/deg
This shows that to rotate the functional arm for 1 degree ,100 Nmm torque is required.
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How to design a torsion spring( Design Hints and critical Point)

•Proportion
•Total No of Coils
•Spring location
The bullet points to be
•Diameter reduction considered during design of
•Spring index the springs
•Winding
•Winding direction
•Arm length
•Bend geometry on the leg
•Torque
• Working condition
•Material specification
•Surface finish specification
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Proportion:
Spring index or inside diameter divided by wire diameter will give proportion. The value from
4 to 14 is best. Ratios of 3 or less often cannot be coiled on spring coiling machines because of arbor
breakage.

Total no of coils:
Torsion springs with less than 3 coils buckle and difficult to test. Total no of coils should be
specified in nearest fractions in the drawing.

Spring Index:
Spring index or spring rate to be calculated inconsideration with the stress.

Spring location:
Torsion springs should be supported by a rod /rivet running through it. During design this
must be considered.

Diameter Reduction:
The reduction of inside diameter during deflection to be computed. During spring operation
the body of the spring deflects and if proper allowance not provided the spring may have premature failure.
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Winding:
Coils of a torsion spring may be closely or loosely wound. The coils should not be wound pressed tightly
together. Tight-wound springs with initial tension in coils do not deflect uniformly and are difficult to test accurately.

Winding Direction:
Direction of coiling should be specified in the drawing whether it is LH/RH

Arm Length:
All wires in a torsion spring is active between the points where the forces are applied. Arm length to be

Bends:
Arms should be as straight as possible. Sharp bends are stress raisers that causes early failure. Bend
radii should be as large as possible. Hooks to be avoided as it may tend to open during deflection.

Torque:
The spring torque value should be calculated and specified in the drawing.
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How to calculate proportions:

Spring index divided by wire diameter or inside diameter of the spring divided by
wire diameter provides the proportions.

Proportion = Spring index / wire diameter

Proportion: 4 to 14 is best
or
Proportion = Inside diameter of the spring / wire diameter

Example:
Spring index = 7.08 Nmm/deg Possible to manufacture
Wire diameter = 1.4 mm
Proportion = 7.08 / 1.4 = 5.05

Example:
Inside dia of Spring = 6 Not Possible to
Wire diameter = 1.6 mm manufacture
Proportion = 6 / 1.6 = 3.75
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Arm Length
Deflection of long extended arms can be calculated by allowing one third of the arm length from the point of
force contact to the spring body converted in coils.
10 mm Force contact point
Spring body
converted into
coils
Deflection

10 mm Force contact point

Spring body
converted into
coils
Deflection

Deflection can be measured from Example: 10 mm / 3

3.33 mm from the spring body : 3.33
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Arm Length
If the length of arm is equal or less than one half the length of one coil it can
be safely neglected in most applications as it cannot deliver the required torque.

Example 5 mm
Wire Ø= 1.2mm

Ø6.0mm

Coil outer diameter : 6.0mm

Mean coil diameter : 4.8 mm
Length of one coil : 2 x pi x r = 2 x 3.14 x 2.4 = 15.07 mm
Half length of the coil = 15.07/2 = 7.5 mm
In this case the arm length is lesser than the half length of the coil. Spring design should
be reviewed and redesigned as it cannot deliver the required torque.
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Diameter reduction
The reduction of inside diameter during deflection to be computed. During spring
operation the body of the spring deflects and if proper allowance not provided the spring
may have premature failure.

Clearance / Allowance

Formula for the inside diameter after load applied
Dl = (n*D)/ ni
Dl=Spring inside diameter loaded
n= No. Of active coils
D=Spring inside diameter non loaded
ni= Number of active springs loaded
ni=n+(q / (2 pi))
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Bends:
Arms should be straight as possible. Sharp bends are stress raisers that causes early failure. Bend
radii should be as large as practicable. Hooks tend to open during deflection.
Large bend radius. Good

Large bend radius. Good

Sharp bends to be avoided

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Torque:
Spring torque value should be mentioned in the drawing. The drawing should capture free condition angle or
manufacturing condition angle, set condition angle and operating condition angle.

X= manufacturing condition angle

M1= Set condition angle
M2 = Operating condition angle

M- moment or torque
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Torsion Spring torque calculation

Torque (T) = E*d^4 / 3667* D*n E= Youngs Modulus N/mm2

d =Wire diameter (mm)
D= Mean diameter of the coil (mm)
n= Total No of Coil
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Induced bending stress on Torsion spring

Spring stress calculation can be done by the standard formula.

The induced bending stress during operation of the spring should be lesser than
the permissible bending stress of the material selected. If the induced bending stress
of the spring is higher than the permissible bending stress then the spring will have
a premature failure.