Abstract:  Recently, due to the rapidly increasing fuel price and strict environmental alregulation, light mass vehicle design is one of the major issues in the auto makers. In this study, magnesium alloy seat frame was used to substitute conventional steel seat frame. Despite of higher material cost, the magnesium seat frame can be less mass as well as an excellent vibration absorption capacity. However, the strength of magnesium is lower than that of steel. Design factor on the most stressed parts of the frame were calculated and sensitivity analysis was conducted using orthogonal array table. The orthogonal array models were simulated with LS-Dyna software. The simulated results were analyzed by Taguchi method to find the most influencing design factors on stress and mass. The strength of new designed magnesium alloy seat frame is improved in both strength and stiffness.  

Key words:  light mass vehicle, magnesium alloy, seat frame, sensitivity analysis, Taguchi method, noise factors