Optimization of Torsion Beam Cross Section Using a Combined FEM-Dynamic Simulation

The compound axle is a space saving suspension component that is relatively inexpensive and easy to install. Therefore it is used in rear suspension system of most front wheel drive passenger cars. This article present an optimum design algorithm for this component. A typical cross section for this the torsion beam of the axle is selected as a basis design. Using finite element methods, kinematics and elasto-kinematics behaviors of the section in vehicle normal maneuvers have been calculated. The acquired dynamic characteristics of the member was entered into a dynamic simulation program and the effect of geometrical parameters of torsion beam on the vehicle handling was studied. Using DOE method a sensitivity analysis was carried out on the torsion beam cross section to achieve an optimum cross section that could satisfy the objective function. The results suggest a V shape design as oppose to the usual U shape for the beam and mark the diameter of the torsion bar as the most effective parameter for an optimum design.