Numerical and experimental analysis of a high pressure die casting Aluminum suspension cross beam for light commercial vehicles

The purpose of the present paper is to enhance and deepen the lightweight optimization in automotive, in particular for commercial vehicles and buses. In detail, aim of this research is to develop a technically reliable and cost effective safety component for Light Commercial Vehicles (LCVs) in aluminum alloy. At this purpose, different solutions of Aluminium Cross beams for an independent front suspension for LCVs have been analyzed, with a weight saving target in comparison with the traditional welded sheet metal structure of almost 40/50%. Moreover further environmental advantages have to be considered; for instance improved corrosion resistance, no painting or cataphoresis required, benefits on recyclability and residual value at the end of life. In detail, the goal of this project has been achieved through: technical and economical study of some different lightweighting solution and selection of the best case; improvement of the solution selected with the help of structural FEA and casting process simulations, a Life Cycle Assessment from cradle to grave (not here described), prototypes realization and preliminary experimental correlation.