Light weighting is a concept in the auto industry about building cars and trucks that are less heavy as a way to achieve better fuel efficiency and handling. Carmakers make parts from high strength steels and innovative designs, as ways to lessen vehicle load. Also Global trends toward CO2 reduction and resource efficiency have significantly increased the importance of this topic over the last years. This study further to this topic is as designing the tubular close profile twist beam with high

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... specific roll stiffness ratio. Basically it is a ratio of roll stiffness to weight. It is all about extracting higher dynamic and durability performance from the structural component with lesser weight. Torsion beam rear-suspension systems have recently been widely used for small passenger vehicles, because of various advantages, including a reduced weight, lower cost, and greater space efficiency, when compared with other types of suspension system. This subject consist entire design and development process of close profile twist beam with the objective of downsizing and improving the performance, integrating the child part or reducing the part count without any impact on the performance in the need of the hour to make it frugal. This objective is realized by smart and innovative design variable section closed profile Crossbeam against conventional bulky assembly of open profile crossbeam with number of child parts such as reinforcements and stabilizer bar. This innovative arrangement renders the thermal and residual stress by better distribution of welding across the assembly. The output of the subject structure will be the better stiffness compared to conventional open profile twist beam design that leads to a considerable saving in terms of weight, simplification of design, improvement in durability performance and manufacturing process. This study deals with roll stiffness calculation and Finite Element Analysis of the rear twist beam suspension system and its optimization through new concept design under static loading condition for high specific roll stiffness. The existing open profile twist beam from one of entry level hatch segment passenger car is selected for the study.