Rapid CNC Prototyping Torsion Springs Custom Double Torsion Spring for Industrial Use

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What Are Torsion Springs?

A torsion spring is a type of helical spring that exerts a torque or rotational force when it is twisted about its axis. The spring is designed to store and release mechanical energy by resisting a twisting motion. The legs of the spring are attached to other components, and when these components rotate around the center of the spring, the spring pushes back in the opposite direction, attempting to return to its original position. This action creates a radial force, making torsion springs essential for applications involving rotation or angular movement.

Materials of  Torsion Springs

The material selection is critical and depends on the required strength, corrosion resistance, and operating environment.

• High-Carbon Steel (Music Wire): The most common and general-purpose material, offering a good combination of strength and affordability.

• Stainless Steel (302/304 or 316): Used for applications requiring excellent corrosion resistance or operation in high/low temperatures.

• Chrome Silicon / Chrome Vanadium: Alloy steels known for their high strength and excellent fatigue resistance, suitable for high-stress and dynamic loading applications.

• Phosphor Bronze / Beryllium Copper: Used for their good corrosion resistance, non-magnetic properties, and excellent electrical conductivity.

Surface Treatments & Finishes

Finishes are applied to improve durability, appearance, and resistance to environmental factors.

• Shot Peening: A process used to enhance fatigue life by inducing compressive stresses on the spring’s surface.

• Electroplating: Common platings include Zinc (offers good corrosion resistance and a shiny finish) and Cadmium (excellent corrosion resistance but less common due to environmental concerns).

• Powder Coating: Applied for thick, durable, and decorative finishes, available in many colors.

• Oxide / Black Oxide: Provides a mild corrosion resistance and a clean, black finish.

• Passivation: A chemical treatment for stainless steel springs to enhance the natural oxide layer for maximum corrosion resistance.

Key Specifications

When designing or ordering torsion springs, the following specifications are crucial:

• Leg Configuration: The shape, orientation, and length of the legs (e.g., straight, hooked, short, long) which determine how the spring attaches to components.

• Torque (Moment): The rotational force the spring exerts, typically measured in Newton-meters (N-m) or Inch-Pounds (in-lbs).

• Spring Rate: The change in torque per unit of angular deflection, measured in units like N-m/degree or in-lbs/360°.

• Wire Diameter: The thickness of the wire used to coil the spring.

• Outside/Inside Diameter: The outer or inner measurement of the spring coil.

• Body Length: The length of the coiled section of the spring.

• Direction of Wind: The hand of the coil (right or left), which determines the direction of the torque.

Application Fields

Torsion springs are ubiquitous in both industrial and consumer products.

• Automotive: In door handles, braking systems, and clutch pedals to provide return motion.

• Consumer Appliances: Found in clothespins, mousetraps, and washing machine doors.

• Industrial Equipment: Used in counterbalance mechanisms, lever returns, and hydraulic systems.

• Medical Devices: Employed in surgical instruments and various equipment requiring precise rotational force.

• Aerospace: Utilized in control surfaces, hatches, and landing gear systems.

An Excellent Case: The Garage Door

One of the most common and critical applications of a torsion spring is in an overhead garage door system.

How it Works:
A large torsion spring is mounted horizontally on a metal shaft above the closed garage door. The spring’s legs are anchored to a central bracket and to the end bearing plates. When the door is closed, the spring is tightly wound, storing significant potential energy.

The Action:
When you activate the garage door opener (or manually lift the door), the mechanism releases the tension. The spring unwinds, transferring its stored energy through the shaft to the cables and drums. This rotational force effectively counterbalances the immense weight of the garage door, making it feel almost weightless and allowing the relatively small motor to lift it easily.

Why it’s an Excellent Case:
This application perfectly demonstrates the torsion spring’s core function: storing and releasing large amounts of rotational energy. It handles high torque requirements and repeated, long-cycle fatigue life, reliably performing thousands of up-and-down cycles over many years. The system’s entire functionality and safety are dependent on the precise engineering and durability of the torsion spring.