In order to reduce the negative effect of lightweighting of suspension components on vehicle dynamic performance, the control arm and torsion beam widely used in front and rear suspensions were taken as research objects for studying the lightweight design method of suspension components. Mesh morphing technology was employed to define design variables. Meanwhile, the rigid–flexible coupling vehicle model with flexible control arm and torsion beam was built for vehicle dynamic simulations. The total weight of control arm and torsion beam was taken as optimization objective, as well as ride comfort and handling stability performance indexes. In addition, the fatigue life, stiffness, and modal frequency of control arm and torsion beam were taken as the constraints. Then, Kriging model and NSGA-II were adopted to perform the multi-objective optimization of control arm and torsion beam for determining the lightweight scheme. By comparing the optimized and original design, it indicates that the weight of the optimized control arm and torsion beam are reduced 0.505 kg and 1.189 kg, respectively, while structural performance and vehicle performance satisfy the design requirement. The proposed multi-objective optimization method achieves a remarkable mass reduction, and proves to be feasible and effective for lightweight design of suspension components.
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