Abstract:

To minimize vehicle mass is an important selection for energy safe and eco-friendly vehicles to
reduce environmental pollution. This paper investigates the design and feasibility of a magnesium alloy seat
frame (MASF) to substitute the existing steel seat frame and improve the seat frame strength while maintaining
the advantages of lower density and higher vibration absorption properties. Sensitivity analysis of MASF
parameters, including stress distribution and acceleration, was made using the finite element (FE) analysis. An
optimization design for MASF in a rear crash test was obtained using a three-level orthogonal array approach of
the Taguchi design matrix, as well as through the correlation of a prototype magnesium seat and an LS-DYNA
simulation. The results show that 40% of mass reduction can be achieved using this approach compared with
using a conventional steel seat structure.

Key words: light mass vehicle design, magnesium alloy seat frame, rear sled crash test, sensitivity analysis