Analytical and finite element simulation of a three-bar torsion spring

The present study is dedicated to the innovative 3-bar torsion spring used as suspension solution for the first time at Lunokhod-1, the first autonomous vehicle sent for the exploration of the Moon in the early 70-ies by the former USSR. The paper describes a simple analytical model for calculation of spring static characteristics, taking into account both torsion and bending effects. Closed form solutions of this model allows quick and elegant parametric analysis. A comparison with a single torsion bar with the same stiffness reveal an increase of the maximum stress with more than 50%. A 3D finite element (FE) simulation is proposed to evaluate the accuracy of the analytical model. The model was meshed in an automated pattern ( sweep for hubs and tetrahedrons for bars) with mesh morphing. Very close results between analytical and numerical solutions have been found, concluding that the analytical model is accurate. The 3-D finite element simulation was used to evaluate the effects of design details like fillet radius of the bars or contact stresses in the hex hub.