Design of Automotive Torsion Beam Suspension Using Lumped-Compliance Linkage Models

Abstract

This paper presents a new method for efficiently and accurately modeling the elasto-kinematic behaviors of torsion beam suspension systems and of other similar classes of mechanical systems, and a design method utilizing the models. The torsion beam is represented as a linkage of lumped mass joined by nonlinear springs, bending and torsion, whose stiffness are identified via off-line computational experiments using nonlinear finite element simulations. A number of such computer experiments are conducted off-line for representative dimensions of torsion beams, and the results are stored in surrogate response models. During design iterations, these surrogate response models are utilized to automatically construct a lumped-compliance linkage model of a torsion beam and integrate it into a multi-body suspension system model that can be simulated using commercial software. Comparison with a nonlinear finite element analysis demonstrates much improved accuracy of the proposed model over commercial flexible multi-body simulation software, with comparable computational speed. Finally, an example is presented on the multi-objective optimization of the cross section of the torsion beam using the developed surrogate response models.