Abstract: Aiming at the common problems and key technologies in the forward development of torsion beams, using numerical simulation methods, the comparative studies were conducted on two types of torsion beams, namely closed tube beams and open plate beams, including key technologies such as torsion beam scheme design, DMU verification, product and process CAE verification, torsion beam deformation numerical simulation, and deformation compensation, providing a certain reference for the forward development of torsion beams by host manufacturers.The main research were as follows. 1) According to the design input, it was necessary to design the beam position and cross-section firstly, with the focus on determining the shear center of the beam. From the numerical simulation results, it can be seen that different beam cross-section designs have a significant impact on the Z-direction distance of the shear center. 2) In checking the kinematic clearance of the torsion beam suspension, compared to the parallel wheel jump condition, the reverse wheel jump condition is harsh, which can easily lead to the risk of interference and wear of the tires and wheel housings. 3) Using numerical simulation technology, the torsional stiffness of two types of torsion beam structures was studied. Compared with open plate beams, closed tube beams have better lightweight effects. Using numerical simulation technology, the external stresses of two types of torsion beam structures under torsion conditions and the internal stresses during the forming process of the two types of beams were studied. If the internal and external stresses at the same position of the beams were superimposed, there would inevitably be a greater risk of fatigue cracking. Solutions should be provided from the perspective of materials, structure, and technology. 4) The deformation of the torsion beam under the action of the vehicle′s offline spring load can have a significant impact on the toe and camber of the torsion beam, and the equivalent toe and camber of the torsion beam should be provided with reverse mechanical angle compensation.

Key words: torsion beam, forward development, numerical simulation, reverse wheel jump, toe and camber