Shape optimization of a torsion beam axle for improving vehicle handling performance

In this study, shape optimization was conducted for a vehicle’s rear suspension torsion beam to improve its dynamic handling performance. To determine the design variables affecting the vehicle roll characteristics, a sensitivity analysis was conducted using the result of a Taguchi experiment with 6 factors in 8 runs. The upper and lower-flange lengths and web thickness of the torsion beam section, as well as the vertical height difference between the inner and outer of torsion beams, were determined as design variables through sensitivity analysis of the opposite wheel travel test for optimization of the torsion beam axle. The Box–Behnken experimental design with 4 factors and 27 runs was performed using the selected design variables and by performing opposite wheel travel analysis according to the experimental design, and the response surface functions of the roll stiffness, roll steer coefficient, roll center height, and mass of the torsion beam were generated. Using these response functions, shape optimization was conducted for the torsion beam of the rear suspension system. Dynamic performance analysis was performed by applying the optimized H-shaped torsion beam to the rear suspension of the vehicle dynamics model, and it was validated that the dynamic response performance of the optimized vehicle was improved.