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© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Customer Success Story
Jaguar
Dr Tayeb Zeguer
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
2010 Jaguar XJ
The 2010 Jaguar XJ is the product of a new generation of design
technology, materials and manufacturing opportunities.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Interior Trim
The interior of the Jaguar XJ combines a traditional look and feel
with modern design and hi-tech features using a mixture of
materials and manufacturing processes.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Design to Manufacture at JLR
Late design changes and long
lead time for the tooling of
plastic parts are a significant
issue for JLR vehicles.
By fully optimizing and
working with part and mold
designers, and the material
supplier, JLR remove the
dependency on their suppliers
and secure valuable design
and manufacturing skills
in-house.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Existing Mold Design
The design of the feed system in an existing mold for the
steering column shroud gave a poor balance between the
cavities and resulted in inconsistent part quality.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
New Mold Design
The proposal for a new mold was to size the runners so that
both components filled at the same time, but analysis showed
that a balance was difficult to achieve.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
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 mold an “S” bend
was introduced and the 2 cavities are now balanced.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Feed System Dimensions
The Moldflow analyst provides detailed dimensions to the Mold
Designer.
Direct Savings expected from this change : $20K
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Sink Marks, Air Traps and Weld Lines
Air Trap
Weld Lines
Sink Marks
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Design Changes Eliminate Molding 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 : $10K
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Conclusion
Mold 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.
JLR secure 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.
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
Benefits of using Autodesk Moldflow to JLR
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 JLR designs is now
in place to create predictive CAE models that reduce the
unnecessary rework and late design changes.
Autodesk Moldflow will ensure confidence ...
at the first mold trial
to manage part and mold cost predictability
to improve both product quality and performance
and avoid unexpected project delays
© 2009 Autodesk Courtesy of Jaguar Land-RoverCourtesy of Jaguar Land-Rover
