Crossmember Design Process – A Case Study

A detailed account of each step of the process in the design and development of a crossmember will be provided. Many of the ideas can be applied to any crossmembers such as radiator crossmember, seat crossmembers, front suspension crossmember or rear suspension crossmember. The discussion in this paper only applies to welded assemblies of stamped sheet metal parts and not castings. A case study is presented to show how a front suspension crossmember was successfully designed and developed.