Lightweight design of automotive front crossbeam assembly

This paper reviews the development course of the front crossbeam assembly for a self owned brand vehicle model based on lightweight and passive safety performance. Combining with an A00 model variant, the paper details the design of extruded aluminum alloy front crossbeam assembly from the perspectives of optimal design, performance verification, lightweight effect and cost control. The following results in the technical and engineering applications have been achieved. The weight of the developed aluminum alloy crossbeam can be reduced by 51 %. The simulated analysis of the collision rigid wall, the 40 % offset hammering as well as the static crush test of energy absorbing box show that after reasonable materials matching and size optimization of the crossbeam and the energy absorbing boxes, the level of crash safety can be improved. The price of aluminum alloy front crossbeam can be lowered by using the extruding die instead of the stamping die to reduce the die cost sharing.