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This paper highlights the application of design optimization in reducing product manufacturing cost without compromising product performance. By using a topology optimization method, the manufacturing cost of a clam shell has been reduced by approximately one-third, while maintaining the NVH performance of the steering column that is connected to the instrument panel (IP) through the clam shell. Two different optimization approaches and two different topological weld deployments are investigated. It is found that a fully-deployed seam weld approach with automatic optimization provides the best design results.

Plastics injection molds are typically subjected to a combination of loadings such as injection pressure, temperature changes, clamping force, and potential interference at seal-off surfaces during manufacturing process. The loadings on the molds are as cyclic as the injection molding cycles. As a result, the molds could fail either in material overstraining or fatigue. In this paper, several failure cases will be presented, along with the FEA stress and fatigue analysis results, to demonstrate the effect of the above mentioned loadings on the mold structural integrity. This paper will also show how the FEA stress and fatigue analyses were effectively employed to determine the mold failure root cause and assist the design modification in a usually constrained time frame.

Plastics manufacturing technology is rapidly changing. The use of process simulation to increase competitiveness has proliferated. Visteon Automotive Systems is committed to developing competent workforce and niche capabilities in plastics processing simulation. In this paper the current capabilities and future development plan for plastic process simulation are discussed. An integrated concurrent engineering process has been developed and implemented to deliver high quality robust plastics automotive products and systems. This paper highlights the technological advancements achieved by Visteon in the field of analytical simulation of common manufacturing processes. In addition, future development initiatives towards the technical competency in plastics manufacturing simulation are discussed throughout the manuscript.