On the Optimization of a Steering Hanger Beam Component

This paper details the application effect of combining various simulation techniques to achieve system optimization. For example, topology optimization can be applied to get the general shape and then thickness optimization can be used to further refine the design.

This study details the optimization of a Steering Hanger Beam (SHB) system capable of achieving high in-vehicle steering frequency. Due to weight considerations, Aluminum was chosen as the material. A new design SHB system was created. After critical parts were identified, they were optimized using both topology and thickness optimization techniques. Simulation model results were correlated with physical prototype results.

The Aluminum SHB yielded one of the company's highest mass production vehicle vertical steering frequencies. Weight was reduced by 39% and parts count reduced by 32% when compared to a Steel design of comparable performance.