Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A tubular twist beam comprises a tubular body 20 including a U-shaped groove 22, tubular end sections 28, and transition sections 26 therebetween. The width w of the U-shaped groove 22 decreases continuously from each transition section 26 to a center point C of the tubular body 20 and is narrowest at the center point C to shift stress from the transition sections 26 to an area around the center point C. The tubular body 20 also includes depressions 24 along side walls 38 of each transition section 26 to direct stress to the underside of the U-shaped groove 22 and further balance the stress levels along the length of the tubular body 20. Thus, the tubular body 20 can be formed with a reduced thickness t and thus a reduced weight without sacrificing performance.

Abstract: 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.

Abstract: A tubular twist beam comprises a tubular body 20 including a U-shaped groove 22, tubular end sections 28, and transition sections 26 therebetween. The width w of the U-shaped groove 22 decreases continuously from each transition section 26 to a center point C of the tubular body 20 and is narrowest at the center point C to shift stress from the transition sections 26 to an area around the center point C. The tubular body 20 also includes depressions 24 along side walls 38 of each transition section 26 to direct stress to the underside of the U-shaped groove 22 and further balance the stress levels along the length of the tubular body 20. Thus, the tubular body 20 can be formed with a reduced thickness t and thus a reduced weight without sacrificing performance.