Client wanted to know if component durability be negatively impacted by switching to an alternative material from a new vendor. VLM simulations determined the new material had a high degree of microstructural grain variation that would increase warranty costs by 85%. VLM analysis also determined that if grain microstructure formation was controlled, product durability could be improved with alternative material. Client put processing controls in place with alternative material and has achieved superior field performance compared to original material and processing methods.
Client wanted to know what was causing lower than expected durability in its component. VEXTEC determined component material was incorrectly heat treated and VLM showed that a fleet of 10,000 showed that 7,500 would fail after 1,000 hours of operation. Further analysis showed that component re-design was also needed to achieve adequate life.
Client wanted to reduce cost of a connecting rod to allow entrance into a price sensitive market without sacrificing durability. VEXTEC identified an optimum combination of changing the forged cooling process & component geometry change that reduced cost and improved durability 22%.
Client asked if the current engine block material could withstand an increase in load. VEXTEC determined the current material specification range of ASTM 2-6 would experience a high degree of failure within the warranty period, equating to $50 million of claims exposure. VLM was used to determine an acceptable material specification range.
Client wanted to know if they could reduce pitting on gears by improving surface finish. VEXTEC performed sensitivity studies that showed durability was significantly increased with improved surface finish.