Design Optimization of Hydroforming Chassis Part for improving Front Suspension Performance

전륜 서스펜션 성능향상을 위한 하이드로포밍 샤시 부품의 설계 최적화

Recently, automotive companies have invested in vehicle weight reduction and clean car development because of oil price rises and environmental problems. In particular, USA car makers have developed the vehicle spending 1 liter per 34km complying with PNGV(Partnership for a new generation of vehicle) and Europe car makers have developed the vehicle spending 3 liters per 100km. The USA government announced "The green car policy" in order to boost production of more fuel effective cars in 2009. According to the policy, it will be restricted to sell the car which spends more than 1 liter per 14.9km by 2020. To satisfy the current situations on automotive market, hydroforming technology has widely adapted vehicle structures such as engine cradle, chassis frame, A pillar, radiator support, etc. However, automotive companies have to consider formability and performance to improve and maximize the benefit from this technology in advance of detail design. The paper deals with one of the vehicle weight reduction methods using tube hydroforming technology and platform commonality in front suspension. FEA simulation is also introduced to evaluate hydro-formability and NVH performance at the beginning of design stage which is the best way to reduce the failure cost.