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
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