VEXTEC’s Case Studies Span Industry and Government Sectors
Read about the successes our clients have had in computational durability prediction using VPS-MICRO software in one of the case studies below.
VIRTUAL PROTOTYPE DURABILITY TESTING
A case study about performing trade studies on countless material & process scenarios before moving to the prototype phase
One of the costliest areas of product development is the testing stage. Even when considering the time and resources already invested in design and prototype fabrication, the testing budget can easily eclipse these. Coupon-level testing, subassembly testing, full-sized test articles…different usage conditions requiring their own testing regimens and protocols. And what happens when something fails in testing where it shouldn’t have, or fails too early? VEXTEC’s comprehensive service and software solution with VPS-MICRO® gives companies the ability to virtually build and test hundreds of different prototype designs.
ADDITIVE MANUFACTURING
Case studies on unlocking the power of AM with VPS-MICRO®
Additive Manufacturing (AM) is perceived by many to be the “holy grail” of industry. The thought of creating the right-sized component, just when it’s needed, and without waste nor the need for much further machining is very appealing. However many sources of variability persist in AM, just as they do in traditional manufacturing processes. And these variabilities have substantial impact on the durability performance of the final components. What are the primary types of variability seen in AM and the obstacles to widespread adoption? How does our predictive VPS-MICRO® technology account for the effects of as-printed surfaces that can drive the fatigue performance of AM components? Find out here.
AMERICAN AIRLINES
A case study where VEXTEC saved $4 Million in component failure costs for American Airlines
American Airlines began experiencing premature failures of their APU Bearings and VEXTEC’s VPS-MICRO® software was used to determine the cause and evaluate options for reducing the component failure. A virtual software model was created which included multiple operating conditions, design and material processing variations, and lubricants. The simulations performed determined an operational change in combination with a lubricant change would eliminate the premature bearing failures. Since the FAA’s approval of the operating change combined with the new lubricant, American has had no failures and has documented savings of $3-4 Million per year.
CAPITAL INVESTMENT
A case study where VEXTEC saved a client more than $700,000 in capital investments
All industrial equipment is designed to operate safely within a certain range of conditions, and in a perfect world, would be operated within its predetermined limits. But often, the designed-for conditions and actual operating conditions are worlds apart, with predictable results: premature failure, unanticipated downtime, unplanned maintenance, productivity losses, unexpected repair and replacement costs, and lost revenue. Such was the case with an industrial manufacturing company that was turning out products for the construction industry using a series heavy rollers operating at pressures above designated operating limits. VEXTEC was asked to determine the root causes of failure, and to identify and evaluate possible corrective actions.
LIFE PROGNOSIS
A case study on a new approach
Gears are among mankind’s oldest mechanical devices, and they continue to play critical roles in a myriad of applications from the esoteric to the mundane. For decades, accepted industry methods for predicting gear health have been adequate. But that’s changing. Gear performance requirements are pushing the design envelope and now require more sophisticated modeling capabilities than what the standard AGMA methods can deliver. In this case study, helicopter gears are profiled, but the VEXTEC durability simulation approach will benefit all types of gears in a broad range of applications, from on & off highway vehicles to aircraft to wind turbine energy production, and more.
VEXTEC’S VIRTUAL LIFE MANAGEMENT® (VLM®) SIMULATION PLATFORM
A case study on the significant impact of VLM simulation
The cardiac implant device market alone is expected to grow to $27 B over the next several years. Medical device firms routinely spend 8% – 10% of revenues in the development of new medical devices. This does not include costs of clinical trials and regulatory approval. There are few operating environments harsher than the human body. Medical device makers need more information about how their products perform in the field than they’re able to get with traditional test methods alone.