The ongoing importance of mechanical testing in the age of simulation

Mechanical testing is often deemed unnecessary, costly and overly time consuming.

In today’s world of vast computer modelling and simulation power, it can be hard to argue against this. 

To cut costs, some companies reduce the amount of time and budgets spent on testing. But unanticipated failures while products are in service have far worse cost and time implications. Test verification is a vital part of any engineering design, and it is often mandatory for some sectors, products and applications.

Key benefits of physical testing include characterisation of material properties, confirmation that products work, validation of computer simulations, collection of empirical data to refine and improve simulations, proof of product improvement, and clear, visible evidence to clients of product integrity.

Clients ask us to help fix products that are unreliable, break or fail, or sometimes just don’t work the way they should. When a completely new design is not feasible, we can work within the confines of the original product. Sometimes, however, we develop completely new designs – from a blank piece of paper to full working prototypes. Both scenarios can benefit from mechanical testing, to demonstrate how the improved or new product performs when subjected to the conditions in which it must operate.

While a lab’s own analysis and computer modelling usually confirms what the outcome of a test will be, testing in a controlled environment to prove functionality is not only cost-effective, but often a real eye opener to the client. 

You simply cannot beat the impact of seeing the product working in a real load condition, rather than just a 3D model or an assembly on screen.

One of our key test rigs is the Large Scale Combined Load Test Rig, which combines compression, torsion and bending. At 18m long and 1.1m wide, the rig was originally designed to test full-scale drilling tools for the oil and gas sector, being capable of subjecting the tools to the conditions seen in a well. As those in this sector know all too well, the loads are severe and can render large and robust mechanical tools useless and badly broken in a short time.