Finite Element Analysis

Race-Tec Sealing Ltd »How we do it »Finite Element Analysis

Finite Element Analysis [FEA] is a computer based method used by Race-Tec for simulating/analysing the behaviour of engineering structures and components under a variety of conditions.

It is an advanced engineering tool that is used in design and to minimise the need for experimental testing.  F.E.A helps to predict how a product or system will react to the application of forces, load cycling, fatigue, vibration and thermal effects.

As specialists in the design and manufacture of mechanical and polymer components Race-Tec understands the value in predicting how a product will perform in use. FEA can be used to design new products, refine an existing product or to ensure that the design will be able to perform to specification prior to manufacture.

Our simulation capabilities help to predict and improve product performance and reliability, reduce physical prototyping/testing, evaluate different designs/materials, optimize designs and reduce material usage and cost.

A variety of programs are used to illustrate the behaviour of the analysis model including colour contour and vector plots, section cuts, isosurfaces, animations, graphs and text output. The results are interpreted and areas of improvement are investigated.

Race-Tec have worked with a wide variety of companies to develop all kinds of products by improving design and performance. For a more advanced explanation of FEA please see the Webinar – Simulation of High-Performance Sealing Products.

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To find out more about how we can help you, please call us on +44(0) 1278 686 823, alternatively leave us a message using our contact form

Reasons to work with Race-Tec

Responsive & innovative design support

Responsive & innovative design support

When investigating a customer's requirements we recognise the need for a fast response and always aim to find a solution, provide the design proposals and quotations within just a few days. As part of our design process we welcome the opportunity to provide input into the handling of the component in terms of its assembly, removal, packaging and identification.

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Bespoke solutions & problem solving

Bespoke solutions & problem solving

All of our products are bespoke solutions either generated as part of the components original design, or solving a current problem. We have the capability to fully analyse existing problems with the use of FEA and/or dynamic testing depending on the availability of components and information.

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CAE - Non-linear FEA, 3D CAD

CAE - Non-linear FEA, 3D CAD

To enable us to work closely with our customers, sharing electronic data, our CAD software Autodesk Inventor suite has full 3D capability and is compatible for data exchange with most CAD systems.

We have a number of CAE packages to aid the design of products, however, the most commonly used and most powerful package is our non-linear Finite Element Analysis. For this we use MSC's Marc software, supported by our own user subroutines to simulate wear etc. The physical properties of most elastomers change significantly with temperature, therefore, we always ensure our simulations use material properties that are as close as possible to the application operating conditions.

Although these tools are mainly used for the development of our products, we have on many occasions supported new and existing customers by offering a design and FEA simulation service.

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Material development & analysis

Material development & analysis

We have a range of testing equipment to cover the physical testing of materials; metallic and elastomers, and for the dynamic testing of products.

For elastomers we have a Wallace Micro (IRHD) and Wallace dead load (Shore A) for hardness, plus a Monsanto tensometer with a thermal cabinet for tensile tests.

For metals we have an Avery Rockwell hardness tester and for the analysis of material composition we have invested in a PolySpek spectrometer from Arun Technology

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Dynamic testing

Dynamic testing

On the dynamic testing side, we have designed and manufactured our bespoke test rig capable of validating a wide range of rotary seals. Of its four test heads, two are used for high speed, and two for high pressure. The rig is fully computer controlled allowing programming of test cycles and logging of key data i.e. torque, temperature, speed, leakage. The high-speed heads can achieve a maximum speed 25,000 rpm, with a maximum fluid operating temperature of 150°C and the ability to apply pressure or vacuum. Whereas, the high pressure heads have a maximum speed of 3,000 rpm and pressure up to 160 bar. Both dynamic and static eccentricities can be accommodated.

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Product performance analysis

Product performance analysis

When a product is working without problems it is not uncommon for used components to be disposed of without taking the opportunity to evaluate them in their used condition. We encourage our customers to return used components at an early stage of development/testing for analysis. This helps us in the development of future products and also provides the customer with feedback and reassurance, avoiding long term problems. The same can of course be done for products that have shown problems.

We have invested in various pieces of equipment allowing us to analyse dimensional and material properties.

The flexible nature of elastomer products makes measurement using conventional contact equipment very difficult. To overcome this we have acquired the latest vision, non-contact co-ordinate-measuring machine. This uses video edge detection (VED) ensuring a repeatable result without relying on the skill of the operator.

Hundreds of data points can be taken in an instant to calculate standard geometry features. The adjustable lens offers a magnification of 30 to 200 times.

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Short lead-times

Short lead-times

Our normal lead-time for the design and manufacture of new products is typically 4 weeks, however, since the period includes the manufacture of new tooling and components, depending on the products complexity this may sometimes be slightly
longer.

The lead-time for repeat orders is largely dependent on the availability of components, however, this rarely exceeds 4 weeks.

For those special urgent projects, miracles can be achieved!

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In house manufacturing

In house manufacturing

We have the capacity to produce 150,000 seals per annum based on single piece manufacturing processes. For higher volume requirements multi-cavity tooling can be used.

All of our manufacturing processes use modern computer controlled equipment, which are maintained through our planned preventative maintenance programme to ensure continuity of supply.

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Small batch capability

Small batch capability

Our normal manufacturing batches are 20 to 50 pieces, with a minimum order quantity of 10 pieces as set-up costs start to become prohibitive. However, if cost is not an issue we can offer batches down to single figure quantities.

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Zero defect quality control

Zero defect quality control

Our Quality Management system is accredited to BSI ISO 9001:2008 by BSI for the design and manufacture of our products. Our aim is to supply to a zero defect through 100% inspection and continuous improvement of our processes.

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Full batch traceability & laser marking

Full batch traceability & laser marking

Our manufacturing and goods receiving controls ensure that every batch of product purchased or manufactured is given a unique batch number. All products sold are identified with our batch number on either the packaging label or marked directly onto the product. This gives us full traceability allowing the identification of which materials were used, who produced it and when it was produced.

With many of the high technology industries like motorsport and aerospace requiring full batch traceability, with individual parts being marked with a unique serial number.

We found it very difficult to find a reliable, local source for subcontract laser marking.

For larger companies, producing high volumes it is easier to justify the expenditure.

For us, customer satisfaction was our priority leading us to invest in our own laser marking equipment.

We are able to offer laser marking on all material types, adding customer logos, part, batch, and serial numbers. Our equipment can handle products up to an approximate maximum size of 500mm x 250mm x 125mm, with a maximum marking area of 180mm x 180mm.

In addition to marking our own products, we are also happy to offer a subcontract service for companies needing a laser marking service. Dependent on volumes, in most circumstances we can offer a very fast turn around.

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Supply chain management

Supply chain management

To ensure we continue to achieve our quality and delivery objectives we have a small supplier base with which we have excellent long established relationships. For each component type we purchase, we have multiple suppliers to ensure continuity of supply.

The performance of our suppliers is monitored in terms of quality, delivery, cost, and offer the same level of support and flexibility as we expect to give our customers.

If within your supplier management you wish for us to procure or deliver to your suppliers we will be happy to accommodate On time delivery your requests.

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On time delivery

On time delivery

We monitor our delivery performance as do many of our customers and we are pleased to say we achieve greater than 95% as an average and 100% with the majority. Typical of Motorsport there are many occasions when we are asked to achieve the impossible and supply a quantity of parts to keep our customers racing.

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Project Management

Project Management

On the more complex projects involving multiple suppliers we are happy to undertake the role of project manager during the design or to the supply of the finished product.

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Complete Design Service

Complete Design Service

If required, we are happy to extend our design knowledge beyond the sealing envelope and assist with the design of associated hardware, whether it be bearings, shafts etc leading to the design and supply of complete sub assemblies. As part of our group of engineering companies we have access to a wide range of products and production techniques.

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Ongoing technical support

Ongoing technical support

Throughout the life of our products we are always happy to offer support should you experience a problem.

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Highly skilled and experienced workforce

Highly skilled and experienced workforce

Due to the technical nature of the products our workforce has been selected for their engineering skills gained through tool making and their experience within the Polymer industry. The majority of our employees have been working in the Polymer Industry for over 20 years, providing us with a wealth of experience.

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Let us know what your requirements are and when it would be a good time to talk and one of our engineers will schedule a call

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