Torsion beam axles for vehicles are disclosed. An example torsion beam axle disclosed herein includes a first side assembly, the first side assembly including a longitudinal member and a receiver. The example torsion beam axle further including a second side assembly, and a cross strut extending transversely between the first side assembly and the second side assembly.

The invention relates to a method for producing a bent torsional profile comprising the following process steps: a) provision of a plate made of planar sheet metal, b) reshaping of the plate through the introduction of a bent trough oriented in the longitudinal direction of the plate in a central length portion (6) of the plate at a distance from the front edges of the plate, forming legs between the trough and the longitudinal edges of the plate, c) reshaping of the legs in such a manner that an open profile is created, d) reshaping of the legs in such a manner that a hollow profile is produced, wherein a longitudinal gap is formed between the two legs over the entire longitudinal extent thereof and wherein an air gap is created between the legs and the trough in the region of the trough, e) joining of the two legs over the entire longitudinal gap.

This torsion beam manufacturing method is for manufacturing a torsion beam including a central portion of which a cross-section orthogonal to a longitudinal direction is a closed cross-section having a substantial V-shape or a substantial U-shape at any position in the longitudinal direction, and a shape changing portion which has a connection region leading to the central portion and including a closed cross-section having a shape different from the shape of the closed cross-section of the central portion. This torsion beam manufacturing method has a compression step of thickening at least the connection region through application of a compression force in the longitudinal direction to at least the connection region of a torsion beam material to obtain the torsion beam, the torsion beam material being formed with the central portion and the shape changing portion.

A semi-rigid axle for a vehicle may include a torsion profile, which extends in a Y direction and is open downward in a Z direction; and two longitudinal control arms, which are connected to the semi-rigid axle and are each connected to the torsion profile by a gusset plate arrangement. Each gusset plate arrangement has a first gusset plate welded to one of the two longitudinal control arms and a second gusset plate arranged at least partially above the first gusset plate. First and second connecting sections of the first and second gusset plates are connected to one another and each of the first and second gusset plates. The first and second connecting sections may be welded to an inside of the torsion profile on both sides in an X direction.

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.

Disclosed are a steel plate for a torsion beam and a manufacturing method therefor, and a torsion beam and a manufacturing method therefor. The steel plate for the torsion beam has the following chemical components in percentages by mass: 0.04-0.085% of C, 0.02-0.5% of Si, 1.3-1.8% of Mn, 0.15-0.5% of Cr, 0.12-0.30% of Mo, 0.058% or less of Nb, 0.15% or less of V, 0.02% or less of Ti, 0.02-0.1% of Al, 0.02% or less of P, 0.005% or less of S, 0.005% or less of N, and the balance being Fe and inevitable impurities. The steel plate has one or two of Nb and V, and the amount of Nb and V satisfies 0.096%<2Nb+V<0.17%. The steel plate for the torsion beam of the present invention has an excellent elongation and excellent cold bending properties while ensuring high strength, and meets the requirement for producing lightweight torsion beams.

An automotive component manufacturing method includes a molding process of pressing a portion of a hollow tube formed from a metal material, or a composite material including a metal and a resin, so as to deform the portion of the hollow tube, from a tube outer side toward a tube inner side, to beyond an axial center of the hollow tube, and mold the portion of the hollow tube into a deformed section deformed with a concave profile; and a deformation process of deforming a location having a high level of residual stress in a closed cross-section configured by the deformed section so as to deform the location out-of-plane.

A die 20 used to form a metal tube into a tubular twist beam part 22 having a U-shaped torsion section 66 is provided. The die 20 includes a punch 44 and side form blocks 34 which simultaneously engage a metal tube and form the metal tube into the tubular twist beam part 22. The form blocks 34 have a curved profile which depends on the desired profile of the tubular twist beam part 22 to be formed. The die 20 includes horizontal spacer blocks 38 and vertical spacer blocks 32 restricting movement of the punch 44 and form blocks 34. The spacer blocks 32, 38 can have various different dimensions and can be easily removed and replaced to adjust the closing position of the die 20 and thus form multiple tubular twist beam parts 22 each having a different dimension and different roll rate.

Torsion beam axles for vehicles are disclosed. An example torsion beam axle disclosed herein includes a first side assembly, the first side assembly including a longitudinal member and a receiver. The example torsion beam axle further including a second side assembly, and a cross strut extending transversely between the first side assembly and the second side assembly.

A torsion beam of a vehicle torsion beam suspension has a closed cross section. A beam center portion has an inverse substantially v-shaped cross section or a substantially v-shaped cross section. Circumference increasing portions having a longer circumferential length toward the beam ends are disposed at opposite sides of the beam center portion. Each circumference increasing portion has a beam width that is a width in the fore and aft direction of a vehicle body, the beam width gradually increasing toward a beam end, and increasing at a higher rate as a position of the beam width is closer to the beam end.