Jaguar Land-Rover use Autodesk Moldflow software to optimise the design and performance of their new car

Jaguar Land-Rover is one of the largest vehicle manufacturers in the world. The interior of the Jaguar 2010 XJ series combines a traditional look and feel with modern design and hi-tech features using a mixture of materials and manufacturing processes. Jaguar have exploited their resources to optimise the design and performance of this car using Autodesk Moldflow plastic injection moulding software.

Background

Late design changes and long lead time for the tooling of plastic parts are a significant issue for Jaguar Land-Rover vehicles. By fully optimising and working with part and mould designers, and material suppliers, Jaguar Land-Rover have removed the dependency on their suppliers, to secure valuable design and manufacturing skills in-house.

Analysis

Existing Mould Design

The design of the feed system in an existing mould for the steering column shroud gave a poor balance between the cavities and resulted in inconsistent part quality.

New Mould Design

The proposal for a new mould was to size the runners so that both components filled at the same time, but analysis showed that a balance was difficult to achieve.

Balanced Feed System

A balance could only be achieved (with acceptable runner diameters) if the length was also increased. So as not to increase the overall size of the mould an “S” bend was introduced and the 2 cavities are now balanced.

Feed System Dimensions

The Moldflow analyst provides detailed dimensions to the Mould Designer. Direct Savings expected from this change is $20K.

Sink Marks, Air Traps and Weld Lines

Design Changes Eliminate Moulding Defects

Subtle thickness changes and the addition of structural ribs were used to …

• Eliminate Air Traps
• Relocate Weld Lines
• Reduce Sink Mark depth

Direct Savings expected from these changes are $10K

Conclusion

• Mould filling analysis and runner balancing eliminated expensive and time consuming tooling changes before the tool was built.
  • Piece price savings – to make a part fit into a smaller press with gating and feed system changes.
  • Additional product design changes were made to eliminate part failures in service.

• Jaguar Land-Rover have secured confidence on modification of an existing tool.
  • removes dependency on the supplier to get it right.
  • reduce the number of late design changes.
  • reduces costly rework.
  • keeps program on time.

• Additional savings are due to reduced product launch time.

Benefits of using Autodesk Moldflow to Jaguar Land Rover

• Autodesk Moldflow has shown excellent capability in assisting in “Right First Time Design”.
• The software is very user friendly and easy to understand.
• A greater understanding of plastic flow on Jaguar Land-Rover designs is now in place to create predictive Computer Aided Engineering (CAD) models that reduce the unnecessary rework and late design changes.

• Autodesk Moldflow will ensure confidence …
  • at the first mould trial
  • to manage part and mould cost predictability
  • to improve both product quality and performance and avoid unexpected project delays