Twist Beam Axle Transverse Strut Variable Wall Thickness
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Solution Overview
Problem
Existing twist beam rear axle transverse struts are heavy due to the need for substantial material to meet performance characteristics, leading to high material and manufacturing costs, and there is a need for a lighter alternative that maintains or exceeds performance without using expensive alloys.
Innovation Solution
A transverse strut with a varying wall thickness, comprising a central section with a first thickness, end sections with a second thickness greater than the first, and intermediate sections with a third thickness greater than the second, formed through a flow forming process that work hardens the material, reducing weight and material costs while maintaining desirable torsional characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If substantial amounts of material are used to form transverse struts through traditional processes, then desired performance characteristics are met, but weight increases
Solution Approach 1:
The transverse strut features variable wall thickness along its length, with thicker sections at locations requiring higher strength and thinner sections where less strength is needed. This local variation in material distribution optimizes the strength-to-weight ratio by concentrating material only where structurally necessary.
Solution Approach 2:
The invention changes the wall thickness parameter along the length of the transverse strut, transitioning from uniform thickness to variable thickness. This parameter modification allows weight reduction while maintaining performance characteristics through strategic thickening at critical locations.
2Weight of moving object
If expensive alloys are used to reduce weight, then weight is reduced, but material and manufacturing costs increase
Solution Approach 1:
Instead of using expensive alloys throughout the entire strut, the invention applies variable wall thickness to conventional materials, concentrating material only where needed. This approach achieves weight reduction without the increased material costs associated with expensive alloys.
Solution Approach 2:
The invention uses conventional, cost-effective materials rather than expensive alloys, achieving weight reduction through geometric optimization (variable wall thickness) rather than material substitution. This maintains ease of manufacture and cost-effectiveness.
3Ease of manufacture
If uniform wall thickness is used, then manufacturing is simpler, but weight and material costs increase
Solution Approach 1:
The transverse strut employs variable wall thickness with thicker sections at critical locations and thinner sections elsewhere. This local variation reduces overall material usage and weight while maintaining structural integrity, overcoming the simplicity advantage of uniform thickness.
4Weight of moving object
If variable wall thickness is implemented, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention modifies the wall thickness parameter along the strut length using flow forming technology. This parameter change achieves weight reduction while the flow forming process manages manufacturing complexity through a specialized forming technique that creates the variable thickness profile in a controlled manner.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a transverse strut with improved torsional performance and reduced weight, lower material costs, and eliminates the need for post-shaping treatments, allowing for longer products from smaller preforms with no scrap material, thus addressing the weight and cost issues of traditional struts.
Implementation Method 1
the deformation step work hardens at least a portion of the resulting transverse strut
Implementation Method 2
deforming material of the preform in an axial direction with at least one roller during the rotating of the preform
Data Source
AI summary
A traverse strut for use in a twist beam axle assembly is provided. The traverse strut extends along a length and presents a central section; a pair of end sections; and a pair of intermediate sections between the central section and the respective end sections. At least a portion of the central section has a first wall thickness, at least a portion of each end section has a second wall thickness that is greater than the first wall thickness and at least a portion of each intermediate section has a third wall thickness that is greater than the second wall thickness. Additionally, at least two of the central, intermediate and end sections is work hardened. The transverse strut has improved performance and lower weight as compared to other known transverse struts.