111 1400 Simon Black Jaguar Land Rover
111 1400 Simon Black Jaguar Land Rover
111 1400 Simon Black Jaguar Land Rover
Niche Volumes
< 10,000 cars per year
Cost structure
needs to be adjusted
for assembly
Production volume
Large Volumes
> 50,000 cars per year
The 4th generation - the next chapter in the history of Range Rover
Component Type
% Part No.
Stampings
88%
Castings
5%
Profiles
3%
Tubes
3%
Other
1%
6%
Al sheet 6xxx
Al sheet 5xxx
Al casting
Al extrusion
HSS steel
PHS steel
1% 4%
15%
37%
37%
by mass
Anticorodal-300T61: Springback
5754 - fit
0.5
0.45
0.4
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
-0.2
-0.1
0.1
0.2
0.3
0.4
0.5
10
Anticorodal-300T61: Springback
Interchangeable tooling
elements:
- Punch radius (12 mm)
- Die radius (8 or 12 mm)
- Drawbead depth (1 mm)
- Blankholder pressure (~10T)
- Draw depths (50 & 75 mm)
11
Anticorodal-300T61: Springback
Sidewall Springback
AC300 T61(183 MPa / 2.00 mm)
Flange Springback
Sidewall Curl
5754 (112 MPa / 1.96 mm)
20.00
15.00
15.00
15.00
C u r l ( )
10.00
10.00
10.00
5.00
5.00
5.00
0.00
0.00
0.00
a n g le ( )
20.00
a n g le ( )
20.00
NG5754
Ac300 T61
12
Anticorodal-300T61: Springback
DVA Study conducted on Sled Runner.
The differences between each material are statistically negligible in terms of variation
Decision to keep Matching Surface tolerance the same at NG5754
Zero impact on manufacturing Bill of Process (BoP)
13
Anticorodal-300T61: Formability
Ac300T61 (~180 MPa)
10118
X350 Front Sidemember
NG5754 2.0mm
Low complexity
243A18
X350 B-pillar Reinforcement
6111T4 2.0mm
Medium complexity
10776
X350 Seat Cross member
NG5754 1.5mm
High complexity
1.
1.
2.
2.
()
3.
3.
()
4.
Dimensional Measurement
4.
Dimensional Measurement
5.
Cosmetic Evaluation
5.
Cosmetic Evaluation
6.
Simulation Correlation
6.
Simulation Correlation
1.
1.
2.
2.
3.
3.
4.
Dimensional Measurement
4.
Dimensional Measurement
5.
Cosmetic Evaluation
()
5.
Cosmetic Evaluation
6.
Simulation Correlation
6.
Simulation Correlation
1.
2.
3.
4.
Dimensional Measurement
5.
Cosmetic Evaluation
6.
Simulation Correlation
14
15
16
17
1.1mm AC170PX
18
Hurdles included
> Robust Heat Treatment Cycle
> Dimensional Stability
> Joining
2012 Automotive World 1st application of
technology on New Range Rover
19
A-Pillar Part
B-Pillar Part
20
A-Pillar
(Current
Production)
A-Pillar
(w/ PFHT)
171
267
Gauge (mm)
2.0
1.3
2.11
1.35
0.64
0.41
B-Pillar
(Current Production)
B-Pillar
(w/ PFHT)
188
269
Gauge (mm)
2.0
1.4
1.64
1.15
0.85
0.59
21
6111 T4 Material
No Impact on Forming
23
25
Total hours per car to make an LWV has reduced by over 50%
27
28
29