Mechanical testing is a vital part of the manufacturing process to determine the material properties and verify the safety of the final product. It plays a pivotal role in ensuring cost-effectiveness and technological advancement. It helps design and manufacturing teams validate the product and improve quality.
Let us understand the process, along with the mechanical test performed –
The categorisation of appropriate test methods is done by analysing the product’s specifications. Engineers often inspect product samples assembling with Finite Element Analysis (FEA) while designing the product. As the FEA does not guarantee appropriate results, mechanical testing is conducted as it provides verifiable data that can be used to refine the FEA. The product can be modified easily and reliably.
Types of mechanical tests performed on product samples –
Tensile Test –
The tensile test is performed to ensure the product’s raw materials meet specified strength and ductility. Although many material suppliers have the means to conduct these tests, they recommend an independent laboratory like TCR Advanced to run tests for additional confirmation. An easy and inexpensive way to prevent future adversities is to confirm that raw materials are within acceptable specifications.
Impact Test –
The impact test is a short-term test that compares the failure behaviour of materials when the component is under rapid load and extreme temperatures. An impact test determines the amount of energy absorbed by a material during fracture. With this test, whether the material is brittle or ductile is identified.
Hardness Test –
In mechanical engineering, indentation hardness tests are performed to measure a material’s resistance to deformation. Several tests involve indenting the inspected substance until an impression is made.
Fatigue Test –
The goal of fatigue testing is to create a fatigue strength curve that describes the material’s capacity to resist cyclic loading across a range of stress levels or to determine the operating circumstances under which fatigue will not occur over the component’s lifespan. Once this curve has been generated, the findings are compared to the part design requirements to ensure that the material will allow the component to last the expected amount of time.
Bend Test –
The bending test is an inexpensive qualitative test that evaluates the ductility and strength of a material. It is widely used as a quality control test. Specimens are easy to prepare, and this test ensures production consistency if conducted correctly and regularly.
Flattening & Flaring Test –
Flare and flat tests are important methods for checking the weld quality of weld pipes. The flattening test is a quality test whose purpose is to determine the ultimate plastics deformation ability of pipe determining whether or not the tube will rupture upon flattening. On the other hand, the flaring test is another quality test that is done to check the ductility of the material by allowing the tube to flare under pressure as per standards.
Should the manufacturer keep a separate budget for these tests?
Yes, they should. The consequence of not performing these tests will lead to the product’s complete failure. Let’s have a look at the consequences if mechanical testing has refrained –
- Chances to fail quality checks increase as the product is restricted to migrate into the market.
- High chances of losing a customer’s trust and potentially valuable contracts.
- In the absence of testing, products are most likely to fail catastrophically.
- Failure Analysis is an integral part of product development. Thus, without these tests, there is no future for the product.
Designated mechanical test laboratory – ‘TCR Advanced’ is one of the diversified and advanced laboratories for third party inspection, in-process testing and advanced material testing. Thus, the product’s lifecycle management becomes easy by conducting the mechanical and chemical tests at TCR Advanced.