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) (SMIRound 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:Torsion Springs— Specification Form O sae ; Nail Lorie ate Danger erent Mean os | Body Leah OD. or Ouse Diane Mandatory Specifications japon feorenied 1. To work over in. (mm) dia. shaft 6. Maximum wound positon turns of position. 2, OUTSIDE DIAMETER Length of moment arm (R) in. (nm a in. (mm) max. or canes ® » See ee i i 8. Direction of helix (Ly R, or optionaD, 3. INSIDE DIAMETER 9. Type of ends __ 3, in. (ai) min. oF Ss in 0 fe ae are OU OF “ES ° :. Stor Hook nds Stig fet Eds a (Nemm) = —_tb.ein, (Nemm) at © ff Qn on i 5. Length of space available in. (mm,) ec mee Tete tale ‘Special Ends: Advisory Data Ree ete ee ta 4, Rate Ib-in,(Nemm) per tun (360°. 2. Mean coil dameter in. nm) Gp = "free angle reference 3. No, of coils Special Information 1. Type of material 5, Bnd use or application 2. Fish 3. Frequency of rotation, —_—yces/see, and working range, O=__"wO= ° deflection. 6. Other 4, Operating temp. °F €C) (SMI Source: Handbook of Spring Desi