In mechanical design engineering it is sometimes necessary to determine how something is going to react under given circumstances. It is a way of checking how a product will behave when it is actually being used for the purpose it is required to serve. We have been involved with many clients over the years who have necessarily needed to complete a sequence of testing in order to proceed with their design and development project. But what is the best way of doing this?
In summary, there are probably broadly two main methods when considering the 'physical aspects' being experienced, so to speak. The first is 'force testing', which in essence, is a way of assessing the physical properties of a component and how it will respond when it is being subjected to a force until it fails or breaks. These forces can be classified as tension, compression, flexure, shear and fracture. The main benefit of physically putting an object under strain is that the results are both visible and tangible. In addition, the ability to see how a material behaves allows for further discussion and if necessary, design manipulation.
We are currently managing force testing for one of our clients as part of our design and development of their components. To this end, we have set up the relevant protocols and have carried out multiple trials, together with the respective validation and verification procedures, which has, in turn, led to design changes to the component CAD data.
The second method is CAD 'simulation testing', which in contrast to the above is a virtual experiment. This means that different product designs can be rigorously tested under various conditions, thus selecting the most appropriate design for development. Designers and manufacturers recognise the value in CAD simulation, though it is only 'as good as the data used' and can significantly reduce product development time and money spent, saving the physical prototype from not being damaged every time another round of testing is tackled.
At present we do not currently perform CAD simulation testing in-house, but just like any other good Jedi, we are very good at assessing if it should be done. So, in the words of every good-natured Star Wars character, “may the force be with you” and if you need help with this service, then please do not hesitate to ask.
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