Abstract
Manufacturing processes for automobile suspension components have generally considered the formability but not the durability of the suspension system, even though the latter is very important in the dynamic performance of the vehicle. Suspension systems should be designed with both formability and durability in mind. This paper describes the design of an optimal forming process to control the cross-sectional properties of the torsion beam in rear suspension systems for increased roll durability. Stamping and hydroforming simulations were performed using the finite element method to determine the optimum tube hydroforming process for producing a torsion beam with the best roll durability performance.
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