Product Validation, Verification and Testing

Virtual Validation

FEA can give virtual insight into the structural integrity of new designs before any capital is spent building parts. Not only can FEA show where new parts may have potential issues, it can be used to diagnose failures seen in the field, and also to optimize designs in order to reduce cost.

In cases where fluid flow is critical (either gas or liquid) CFD can be used to optimize flow and minimize turbulence, or to predict how two different liquids are mixing, etc. It can also be used in conjunction with FEA when a transfer of fluid causes a resultant force that needs to be considered when doing structural analysis. There are many types of engineering simulation and analyses that Matrix Engineering Consultants performs either as a stand-alone service or integrated into our projects.

Some of the capabilities at Matrix Engineering Consultants include:

Simulation Tools

  • ANSYS/ANSYS Workbench
  • Hyperworks Suite
  • NX Nastran
  • CREO Simulate
  • SolidWorks Simulation
  • AcuSolve
  • KISS Soft
  • TileFlow
  • BoltCalc
  • Simulink

Simulation Types

  • FEA Structural
  • Fatigue
  • CFD
  • Bolted Joint
  • Gears & Powertrain
  • Kinematic
  • Dynamic
  • Tolerance Analysis
  • Hydraulic

Field & Lab Data Acquisition

Data acquisition plays a critical role in both new product development and in troubleshooting existing products. Having accurate product data enables MEC and its clients to gain a thorough understanding of current product performance. This data allows engineers to make informed design decisions which will reduce product development time by getting the design right the first time. The data also aids analysts in establishing the root cause of a product failure. MEC has proven experience in using test data to;

  • Develop load cases from machine/vehicle operation to use as a basis for engineering calculations and simulation
  • Enable the correlation of strain measurements to structural FEA results and design life predictions
  • Determine or verify performance characteristics of various components or systems
  • Better understand the application and help determine the root cause of failures

MEC has the ability to acquire test data in the lab or field using a suite of hardware from National Instruments . The hardware is housed in a rugged and watertight enclosure which can be battery powered and so is completely portable. The unit enables MEC to collect time synchronized data across multiple instruments and sensors.

  • Acceleration data
  • Strain measurement gauges
  • Temperature sensors
  • Position sensors
  • CAN data from sensors/instruments that already exist on a machine/vehicle
  • Pressure sensors
  • Flow rates – liquid and gas
  • Sound levels
  • Video capture

Specialized Test Stand Design

Using a combination of our data acquisition, machine design, and control systems capabilities, MEC can develop mechanical and electronic test systems to verify/validate machine systems or component performance.

  • Simple instrumented fixtures with manual testing and data capture
  • Automated testing of complex systems with customized control dashboards and reports.
  • Software testing - MIL & HIL

Fastener Testing

Torque Tension Testing

MEC is experienced at executing torque-tension testing according to industry standards such as ISO 16047 Torque/clamp force testing.

The relationship between input torque and induced tension in a specific fastener application can be determined by testing the fastener with a calibrated load cell and torque device. Based on this data, the nut factor or total coefficient of friction can be calculated and used to evaluate the effect of various fastener finishes, coatings, lubricants and manufacturing processes. By repeating the test on a sample of the fasteners, the variation in the torque-tension relationship, can be established for an application. This will give you increased confidence in your fastener designs and manufacturing processes.

Torque to Yield Tests

MEC can be perform tests on actual fastened assemblies to obtain torque-angle graphs and to establish the torque to reach the yield strength of the bolt. Such data can be used to establish the appropriate torque-angle requirement for the specific fastener and joint. This technique has a distinct advantage because the actual joint and fastener can be tested without compromising the joint stiffness through the introduction of a load cell.

Laboratory Equipment

  • PCB L&T Model 962 Portable Transient Recorder
  • Rotary Torque-Angle Transducers
  • Load Cells