As a manufacturer, your parts and products are designed to be used extensively and should ideally perform for many years without fear of product failures. Testing a product’s mechanical durability is essential as you work through potential weaknesses to ensure this ideal performance. Applied physical force can determine vulnerabilities and prevent product failures in the early stages of development as you work to improve your finished product.
Mechanical endurance testing is required to test these products safely and effectively in a variety of extreme conditions. These tests are designed to calculate your products’ reactions to extreme stress safely and effectively with controlled testing conditions.
What Is Mechanical Endurance Testing?
Electronics, automotive parts and other heavy-use items endure extreme stress levels daily through repeated and prolonged use. When a product is subjected to this repeated stress, it can be prone to failures even if it’s never reached its static stress limitations. Although calculating static mechanical stress limits is useful, it fails to evaluate a product’s overall lifetime, as it can’t account for damage stemming from prolonged use in different environmental conditions. Mechanical endurance testing is thus needed to measure this damage over a product’s lifespan.
Mechanical endurance testing is used to determine whether a product can withstand the processing load it’s expected to endure during heavy use over an extended period. Lab engineers observe memory consumption and performance quality while the specimen undergoes simulated conditions similar to the stresses it will encounter during use.
Different tests use physical forces such as vibrations, shock stresses and strains to establish the product’s boundaries of use and prepare it for better quality control before it’s manufactured and sold. These tests ensure that performance and reaction times are degraded no more than a specified percentage over the course of testing.
How Does Mechanical Endurance Testing Work?
Specimens are sent to a mechanical endurance testing lab, where engineers perform a variety of quality control tests using gauges and other machinery. Different machines are used to test various aspects of a product’s strength and endurance, and testing can be customized to meet individual industry standards.
During testing, technicians observe a variety of factors that contribute to the part’s or product’s mechanical longevity. A combination of various testing methods ensures that nearly all aspects of the product’s functionality are accounted for.
Some of the potential failure methods targeted through mechanical testing include:
- Adhesion and bond strength
- Flexural strength and fatigue
- Tensile strength and impact
- Material toughness
- Mechanical wear and circuit shortages
- Memory and performance quality
- Overall durability
Testing can take days or weeks, depending on the type of product and methods used. After a thorough analysis of the system’s reaction, results are shared with the manufacturer. Technicians and manufacturers then work together to fix any outstanding issues before the product’s release.
Types of Mechanical Testing
Many types of mechanical endurance testing can be performed to emulate the entire life cycle of a product, depending on industry standards and unique product needs. Some of the most common types of testing include fatigue, push-pull-press and open-close testing:
- Fatigue testing: Experts assert that fatigue causes between 50 and 90 percent of all mechanical failures. While sources vary on the exact percentage, fatigue analysis of engineering material is vital towards ensuring the longevity of a finished product. In fatigue testing, engineers determine localized and progressive structural damage caused when a material experiences cyclic loading. Tests measure the product’s resistance to cyclic stress over several stress levels.
- Push-pull-press testing: Also known as tensile, compression and impact testing, push-pull-press tests calculate a material’s resistance to heavy impact from tension or compression. Tests measure the force required to pull, push or press an object to its breaking point, which determines the maximum amount of tensile stress a material can undergo before failure. These tests are particularly useful in industries such as mechanical and structural engineering.
- Open-close testing: Hinges on doors, windows, flip phones, garage door openers and many other products need to be tested extensively to ensure durability over many years. Open-close testing machinery quickly simulates years’ worth of use.
Benefits of Mechanical Endurance Testing
Many industries require mechanical endurance testing to ensure compliance with industry standards and federal regulations. But even when testing isn’t required by law, it can still be vital to ensuring product safety. Electronics and other materials that undergo extreme amounts of stress are susceptible to overload, which could be dangerous to consumers’ health and well-being. Mechanical endurance testing can prevent disastrous product failures, lawsuits and warranty expenses while increasing brand loyalty and product quality over competitors.
Mechanical endurance testing helps you locate fundamental flaws in a product’s structure, which will guide you as you improve the product’s quality before it’s placed on the market. This information is vital to ensuring sustainability for its intended use. Locating your product’s weaknesses will also make your designs more cost-effective while improving overall product excellence.
Materials of all types can be improved through this testing. Some of the most common products tested using mechanical endurance testing include:
- Computers and other electronics
- Medical equipment
- Automotive parts
- Aerospace and defense equipment
- Consumer electronics
- Energy generators
Contact Quality Testing Services, LLC for Your Mechanical Endurance Testing Needs
For over 20 years, Quality Testing Services, LLC has been an industry leader in product testing for leading manufacturers worldwide. We offer numerous testing services, including mechanical endurance testing, and our highly skilled team is dedicated to meeting your unique needs.
At QTS, we’re small enough to dedicate our time and energy to each project, while we’re large enough to deliver reliable results and exceptional customer service. Our facility offers some of the most advanced mechanical endurance testing options available today.
If you’re looking for a leading testing company that provides flexibility and fair pricing, turn to QTS. We work with you to comply with your company’s individual needs and industry demands and will collaborate with you to be a reliable partner. Contact us online or call us at (714) 903-1155 to learn more about our testing services.
- In-house custom fixture design and fabrication
- Life Cycle
For more information, call us at (714) 903-1155 or request a quote.