Competitive Hub Sample Analysis
March 26, 2013
Confidentiality Statement
This information is intended only for the person or entity to
which it is presented and may contain confidential,
proprietary and/or privileged material. Any review,
distribution, or other use of this information by persons or
entities other than the intended recipient is prohibited.
VCS
Data classification: Confidential
02/04/2012
2
Wheel Bearing - Definition
A device that supports, guides, and reduces the friction
of motion between chassis parts and a rotating axle
Driven Axle
VCS
Non-driven Axle
Data classification: Confidential
02/04/2012
3
Wheel Bearing – Cross Section
Seal
ABS Sensor
Raceway
Ball
Retainer
Wheel
Flange
Inner
Ring / Raceway
VCS
Data classification: Confidential
02/04/2012
4
Feature Outline
Visible Design Features
•
•
•
•
Lip Seal
Ball Size
Ball Spacing
Raceway Design
Hidden Design features
•
•
•
•
•
•
VCS
Tolerances
Roundness/Roughness
Preload
Heat Treatment
Non Drive / Roll Forms
ABS
Data classification: Confidential
02/04/2012
5
Lip Seal
MOOG 513179
Entry 513121
Double lip seal
Quad-lip seal
Primary ejector seal
Stainless steel housing
MOOG quad lip seal integrates exterior material ejector feature, protecting triple
inner seal, and providing for superior sealing on a stainless steel sealing surface
Entry seal is older dual lip seal technology, inexpensive to manufacture , and
prone to fail as sealing surface is exposed to environmental conditions
VCS
Data classification: Confidential
02/04/2012
6
Lip Seal Critical Features
MOOG Seal Design and Assembly
•
•
•
•
•
Patented premium seal design
Four separate sealing lips
Prevents entry of water and other contaminants
Stainless steel riding surface for durability
• No corrosion
Cartridge design ensures proper alignment for
maximum seal effectiveness
Entry Design and Assembly
•
•
Double lip design
Increased potential of contaminants entering
bearing environment
Seal
Disintegration
VCS
Data classification: Confidential
Raceway
Contamination
02/04/2012
7
Ball Size
MOOG 513179
Entry 513121
Smaller ball
diameter
Larger ball
diameter
MOOG Ball diameter and race way are large per OE design
Entry product has lower cost smaller bearings and race way
VCS
Data classification: Confidential
02/04/2012
8
Ball Size Critical Features
MOOG Ball Diameter – 5.0mm
Entry Ball diameter – 4.3mm
Less surface area
Greater surface area
•
•
VCS
MOOG - Larger ball size
•
Creates higher load carrying capacity
•
Decreases stress on the ball and raceway
•
Improves load carrying capacity and reduces stress
Competitive product - Greater chance of bearing failure.
Data classification: Confidential
02/04/2012
9
Roller Bearing Critical Features
Raceway
Roller
•
•
Roller
•
Proper crowning required to allow for line to line contact
•
Improper contact generates excessive heat and early failure conditions
Competitive bearings
•
VCS
Improperly crowned bearings load on the edges causing premature wear
Data classification: Confidential
02/04/2012
10
Ball Spacing
Critical requirements
• Distance or spacing between the rolling elements
• Larger the spacing, higher the load caring capacity of the bearing.
MOOG 513179
Entry 513179
17mm
20mm
• Competitive spacing is only 17mm with smaller ball size
• Spacing alone results in 15% lower load caring capacity than OE design.
VCS
Data classification: Confidential
02/04/2012
11
Raceway Design
Outer Ring Cut-a-way
Results of improper design and manufacturing of the raceway
• Spalling of the rolling elements
• Failure of the hub
Entry 513179
MOOG 513179
Increased
surface area
more
expensive
process
Cost reduced
raceway no
curvature
•
MOOG incorporates a superior and more expensive process that dramatically
increases the surface area contact between the ball and the raceway improving
the life of the bearing
•
Entry low cost design has minimal contact area between ball and raceway.
VCS
Data classification: Confidential
02/04/2012
12
Summary Visual Findings
• MOOG Better seal design
• MOOG Larger ball size
• MOOG Large ball spacing
• MOOG Superior raceway design
•
•
VCS
Design features visible to unaided eye
Visual examination MOOG product is superior
Data classification: Confidential
02/04/2012
13
Bearing Tolerances
•
•
•
VCS
Difference between properly
designed and ground race ,
matched vs improper ball
size, less the 10 Microns
Impossible to see difference
with unaided eye
Good looking bearing is not
indication of quality
Data classification: Confidential
02/04/2012
14
Raceway Design Critical Features
•
Features critical to standard
raceway design include precision
grinding, polishing, and hardening
to match the OE vehicle load
requirements
•
MOOG raceways are polished to
stringent F-M standards and utilize
matched ball sizing to provide
optimal interface between the
raceway and the rolling element
•
VCS
These features reduce the
incidence of spalling and brinelling
Brinelling is a pit
in the raceway
typically caused
by use of low
grade steel and
improper
hardening of
raceway
Data classification: Confidential
Spalling is when a
rough surface or poor
design causes bearing
to weld to race way
and then break free
tearing material away.
02/04/2012
15
Roundness / Roughness
•
Each imperfection or deviation increases the stress causing heat, potential
spalling and possible failure.
•
Similar to your car running over continuous pot holes at high speed
VCS
Data classification: Confidential
02/04/2012
16
Heat Treat Patterns
Heat treatment is an integral part of bearing design
• Improper heat treat results in spalling and premature failure
Entry 513179
MOOG 513179
Uniform heat
treatment
Thin / inconsistent
heat treatment
•
MOOG incorporates a superior and more expensive process providing uniform
heat treatment
•
Entry low cost design does not demonstrate a consistent profile
VCS
Data classification: Confidential
02/04/2012
17
Federal-Mogul Material Evaluation
Heat treatment patterns (F-M study entry brands)
• Spindle raceway
• Heat treat depth min 1.8mm
• Hardness 58HRC
• Hub raceways
• Heat treat depth
• Outboard - min 1mm
• Inboard - min 0mm
• Hardness 64HRC
• Inner ring
• Hardness 64HRC
•
•
VCS
Hardness levels in the raceways are acceptable.
• However the spindle raceway hardness is at the minimum of the acceptable range
Heat treatment pattern in the hub raceways is not acceptable:
•
Inboard raceway is not completely hardened
•
Outboard pattern is less deep than standards industry practices
Data classification: Confidential
02/04/2012
18
Bearing Tolerances & Preload
Preload
• Properly designed, manufactured, and tolerance bearing is squeezed together
Life vs. Axial Clearance
High Preload
300000
200000
150000
100000
L10 Life (km)
250000
50000
Preload
Low Preload
0.05 0.04 0.03 0.02 0.01
0
0 -0.01 -0.02 -0.03 -0.04 -0.05 -0.06 -0.07 -0.08
Axial Clearance (microns)
Properly preloaded bearing - significantly more life
• Without preload – early bearing failure
•
Rolling elements slide instead of roll
• Excessive preload causes rolling elements to over heat and spall
VCS
Data classification: Confidential
02/04/2012
19
Non Drive Bearing Design
OE design standards have dramatically increased the number of cold formed
non drive hub designs in the market. This design family requires a high quality
steel in terms of cleanliness and extremely tight control on process to properly
manufacture. Failure to do so results in formation of microscopic cracks that
after time can grow and result in the wheel coming off the vehicle.
Flange is rolled over and holds
the complete bearing assembly
together (Roll form)
Rolling causes significant stress
in the steel. Here is a computer
model showing the higher stress
for the part. More Red the higher
the stress
VCS
Data classification: Confidential
02/04/2012
20
Non Drive Bearing Design
Safety critical features
A
The pictures below show properly roll
formed part under 100x magnification
A
Clearance “A” = 0
NO folds smooth surface
Fig 2. 2 views of the forming area in the hub of FM 413124 bearing.
VCS
Data classification: Confidential
02/04/2012
21
Non Drive Bearing Design
Safety critical features
A
The pictures below show an improperly roll
formed part under 100x magnification
A
Clearance “A” = 0
Typical of folds/cracks
found in entry cost product
Cracks or fold are very common in BCC manufactured hub product. All
cracked/folded parts will not result in a wheel off condition, however, this is a
very critical parameter to control as it is not possible to inspect during or after
manufacturing
Fig 2. 2 views of the forming area in the hub of FM 413124 bearing.
VCS
Data classification: Confidential
02/04/2012
22
Non Drive Bearing Design
100 x magnification
500 x magnification
At 500 x magnification you can see cracks have started to form at
the tips of the machining marks left during manufacturing
Fig 2. 2 views of the forming area in the hub of FM 413124 bearing.
VCS
Data classification: Confidential
02/04/2012
23
Non Drive Bearing Design
Sample of data collected by Federal Mogul on entry level products
Inspection Results
Inspection Results
Part Number
512202
512268
512288
VCS
Brand
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Entry brand 1
Sample
Crack / Defect Reference
Requirement Judgement
#
at 500x
at 100x
1
--OK
C, F
2
--OK
F
3
F
Found
A, C, F
4
F
Found
F
5
F
Found
F
6
--OK
B, F
1
F
Found
B, C, F
2
[B], F
Found
[B], C, F
3
F
Found
B, F
4
--OK
F
5
F
Found
F
6
F
Found
F
1
--OK
B, F
2
B, F
Found
B, F
Entry brand 1
3
[C]
Defect Found
B, [C], F
Entry brand 1
Entry brand 1
Entry brand 1
4
5
6
F
B, C, F
F
Found
Found
Found
F
B, C, F
F
Part
Number
513124
513188
513196
513230
Brand
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Entry brand 2
Data classification: Confidential
Crack /
Sampl
Reference
Requireme Defect
e#
at 500x
nt at 100x Judgement
1
B, F
Found
B, F
2
F
Found
F
3
--OK
B
4
1
--OK
B, F
2
F
Found
B, F
3
--OK
--4
--OK
--1
C, F
Found
B, C, F
2
F
Found
C, F
3
F
Found
C, F
4
C, F
Found
B, C, F
1
--OK
--2
C, F
Found
B, C, F
3
F
Found
A, C, F
4
--OK
F
02/04/2012
24
ABS Critical Features
• ABS assembly
•
•
•
VCS
Requires a precise
tolerance stack between
the sensor and the encoder
ring
ABS sensor lights one of
highest warranty items for
hubs
F-M product is 100%
inspected for ABS signal at
end of the assembly line
Data classification: Confidential
02/04/2012
25
Dynapak vs. MOOG
Dynapak - 515036
MOOG - 515036
A
A
B
B
MOOG Differentiation
•
•
VCS
More Robust support in the roller
Deeper spline ensures proper mating of CV shaft to hub spline
Data classification: Confidential
02/04/2012
26
Feature Outline
Design Features you can see
•
•
•
•
Lip Seal
Ball Size
Ball Spacing
Raceway Design
Design features you can not see
•
•
•
•
•
•
VCS
Tolerance
Roudness/Roughness
Preload
Heat Treating
Non Drive Hubs / Roll Forms
ABS
Data classification: Confidential
02/04/2012
27
Quality Gap in Marketplace
• Significant quality difference between MOOG premium
sealed hub assemblies and economy/low-cost hubs
–
–
–
–
VCS
Lab testing
Defect analysis
Warranty analysis
Customer feedback
Data classification: Confidential
02/04/2012
28
OE Quality from OE Supplier
• Provides “assurance” that fit and
form matches OE
• “Seal of Approval” of FM quality
control
• 70% of MOOG Hub Assemblies
are manufactured by F-M Partner
– Tier 1 OE supplier
– OE quality product from OE supplier
– Balance of line sourced from OE
suppliers
• Premium OE competitors only
manufacture 30% of volume and
source the remaining parts
VCS
Data classification: Confidential
02/04/2012
29
Product Requirements
• Product design requirements
•
Complies with OE design dimensions for ease of installation
•
Has the same ABS signal requirements of OE design
•
Has the internal design intent of the OE (integral races)
•
Wheel stud requirements for safety
•
Seal Integrity
• Product performance requirements
•
VCS
Validation of product from Aftermarket suppliers follows F-M validation
process
Data classification: Confidential
02/04/2012
30
Test Validation
• Wheel bearing fatigue life test:
•
•
VCS
Rolling element fatigue life for bearing durability
Bending fatigue life for spindle flange fatigue strength of bearing
during vehicle life
Data classification: Confidential
02/04/2012
31
Test Validation
• Wheel bearing mud / salt slurry test:
•
Proper performance of the sealing system
• Wheel bolts retention test:
•
VCS
Assembly retains the wheel and rotor on the vehicle
Data classification: Confidential
02/04/2012
32
F-M vs. Competition
Durability Benchmark Test
(Cycles)
3000000
2500000
2000000
F-M
1500000
Competition
1000000
500000
0
Unit 1
VCS
Unit 2
Unit 3
Data classification: Confidential
Unit 4
02/04/2012
33
F-M vs. Competition (MOOG vs. Entry)
515054
Durability Benchmark Test
7,000,000
test cycles to failure
Higher is better
All MOOG samples were
stopped at 6mill cycles
6,000,000
5,000,000
4,000,000
F-M
3,000,000
Competition
2,000,000
1,000,000
Unit 1
Unit 2
Unit 3
test sample
Unit 4
Based on Weibull analysis 90% of the tested Competition parts should
last at least 10,000 miles. 90% of the tested F-M parts should last at
least 540,000 miles.
VCS
Data classification: Confidential
02/04/2012
34
F-M vs. Entry Competition 513124
Bearing Fatigue Life Test
12,000,000
10,000,000
8,000,000
6,000,000
4,000,000
2,000,000
0
MOOG Hub
MOOG Hub
MOOG Hub
National
Hub1 2 National
Hub2 1 National
Hub 33
Economy
Design 4
Economy
Design 3
Economy
Design 1
Economy
Design 2
• Bearing wear and noise are notorious early failures for
entry product
• MOOG out-performs entry life by 8X
VCS
Data classification: Confidential
02/04/2012
35
F-M vs. Entry Competition 513124
Mud & Slurry Test
40.00%
30.00%
20.00%
10.00%
0.00%
Nat
ional
MOOG
1
Hub 2
Nat
ional
MOOG
2
Hub 3
Nat
ional3
MOOG
Hub 4
Nat
ional
MOOG
4
Hub 1
Economy
Design 4
Economy
Design 1
Economy
Design 2
Economy
Design 3
• High amount of mud and other debris indicate poorly sealed unit
• Exposure to contamination causes premature failure and noise
• Typical OE style design is less than 3%
VCS
Data classification: Confidential
02/04/2012
36
Hub Assembly Failures
• Warranty analysis indicates three primary complaints on
defective product
– New ABS problem after hub assembly replacement
– Noise from wheel end
– Premature bearing failure
ABS and Noise related problems are critical concerns for
installers because they are the most likely reasons their
customer will be unhappy with repair job.
VCS
Data classification: Confidential
02/04/2012
37
Problem Solvers
• “Problem Solver” heritage
–
–
–
–
VCS
Better than OE
Solve know weaknesses
Eliminates installation issues
Improved durability
Data classification: Confidential
02/04/2012
38
MOOG Hub Assemblies
•
•
•
•
•
•
VCS
Premium design
Engineered to be better than OE
Highest quality
Safety critical
Number one brand in category
Marketing support
Data classification: Confidential
02/04/2012
39