Testing resistance, durability, fatigue, functionality

BOSMAL performs various types of resistance, durability, fatigue and functionality tests on:

• assemblies and car parts on multi-channel test benches,
• gearboxes,
• suspension components for motor vehicles (rocker arms, shock absorbers, springs, steering heads, hubs, wheel bearings),
• elements of the body and equipment of passenger cars (seats, doors, locks, window lifters, gas springs, etc.),
• elements of the drivetrain (axles, shafts),
• couplings (mechanisms, discs, claddings),
• elements of the steering system (gears, rods, ball joints, steering wheels),
• brakes (drums, discs, jaws and inserts – brake pads) on a LINK test bench,
• elements of the braking system (pumps, cylinders, equalizers and pressure regulators, clamps, servos, wires, connectors),
• pedal assemblies,
• seat belts,
• ball coupling devices and towing devices,
• metal and rubber elements,
• springs,
• fluid tranfer lines in terms of leaktightness and resistance to tearing,
• fuel lines,
• cables and control cables,
• threaded connectors (measurement of forces and moments, determination of coefficient of friction),
• durability and functional tests of windscreen wiper assemblies,
• durability tests of electric fans,
• tests of the mechanical resistance of glass,
• durability and functional tests of external and internal lighting,
• durability and functional tests of alternators.

Measurements of characteristics and fatigue tests of shock absorbers, gas springs and suspension springs

Force and torque measurements

Measurement of force as a function of displacement

Technical parameters

• Force calibration range: ± 92 kN
• Torque calibration range: from 0.5 to 6000 Nm
• Temperature: ambient
• Force signal recorder
• Torque signal recorder

We perform various measurements and tests force versus displacement, among others:

Measurements on a Thȕmler TH 2730 testing machine

Measurements on a Thȕmler TH 2730 testing machine – a classic single column testing machine for measuring force in the range of up to 3000 N with replacement handles for samples and force sensors.

Measuring range

• Displacement: 0 – 500 mm
• Speed: 0 – 700 mm/min
• Force range:
  • 0–5 N
  • 0–30 N
  • 0–100 N
  • 0–3000 N

Clutch pedal characteristic

Another example of this type of testing is a measurement of the clutch pedal characteristics, which measures the force on the clutch pedal to its stroke.

Measurements of forces and torques in threaded joints

Measurements on threaded joints on a „LORENZ” device

• coefficient of friction
• torque on the screw thread
• torque under the screw head
• axial force relative to the tightening torque

Normal thread: M6x1, M8x1,25, M10x1,5, M12x1,75, M14x2, M16x2

Fine thread: M10x1,25, M12x1,25, M14x1,5.

Required bolt length range:

• M6 x 1: 18 mm – 59 mm
• M8 x 1.25: 20 mm – 61 mm
• M10 x 1.25: 20 mm – 65 mm
• M10 x 1.5: 20 mm – 69 mm
• M12 x 1.25: 25 mm – 103 mm
• M12 x 1.75: 25 mm – 124 mm
• M14 x 1.5: 25 mm – 110 mm
• M14 x 2: 25 mm – 110 mm
• M16 x 2: 25 mm – 84 mm

Skidmore Wilhelm

Skidmore Wilhelm – used to measure stress for many types of both threaded bolts and nuts.

Scope

• Screw sizes M5 – M16
• Force 0 – 91 kN
• Together with angle and torque measurement up to 200 Nm

Ultrasonic thickness gauge 38DL PLUS

Ultrasonic thickness gauge 38DL PLUS is designed to measure the part thickness for industrial and commercial applications, i.e. glass, plastic, metal, ceramic and composite materials. It can also be used to indirectly measure the force in threaded connections in hard-to-reach places. (Measurement of the extent previously prepared screws)

Parametry

• Material thickness 0.08 – 12.5 mm
• Resolution 0.001 mm or 0.0001″

Static and dynamic twist tests

Static and dynamic twist tests of various components

Technical parameters

• Max. torque: ± 5650 Nm
• Max angle: ± 50° (static test), ± 45° (dynamic test)
• Frequency: up to 10Hz
• Temperature: ambient
• Load signal acquisition

Static and fatigue testing of shafts

• ES6G91-3B436-AA
• ESBK21-3B436-AA; 05.04-E-309
• VE6KMW-3B436-AA / BA
• 1009190

Static and dynamic component compression/stretching tests

Static and dynamic compression/stretching tests of various components

Technical parameters

• Maximum force: ± 92 kN
• Maximum displacement: ± 125 mm
• Frequency up to 80 Hz
• Temperature: ambient
• Load signal acquisition

We carry out:

• Durability tests of mounting straps (see photo)
• Durability tests of other parts

Measurements of the characteristics of metal-rubber components

Test range

1) Static characteristics

• Axial
• Radial
• Rotational
• Diagonal

2) Strength testing of rubber-metal connections

Testing apparatus

• MTS 810 durability testing machine
• MTS hydraulic torsion testing machine
• Linear actuators with MTS FlexTest 60 and FlexTest SE controllers

Software

• TestWorks 4 – MTS
• MultiPurpose Test Ware (MPT) – MTS
• MultiPurpose Elite (MPE) – MTS
• Basic Test Ware (BTW) – MTS

Durability testing – multichannel loading

Dedicated mechanical testing

We have the ability to construct various simple test bench setups, based on our base of electro-mechanical and measurement equipment. For measurements we use pressure, force, displacement, rotation, angle and other transmitters that can be combined with measuring amplifiers that also enable reading from a CAN network. For the supply of force, we can use various types of hydraulic and pneumatic cylinders, electric motors or human muscle.

Test devices used for fatigue testing

Durability/fatigue testing – failure probability analysis

Weibull++7 software – ReliaSoft

• Weibull++ provides the most comprehensive set of tools for the reliable analysis of data, the execution of statistical calculations and the generation of plots and reports. The software supports the following models: Weibull Exponential, Lognormal, Normal, Generalized Gamma, Gamma, Logistic, Loglogistic, Gumbel, Bayesian-Weibull.
• Parameter estimation methods: MLE, RRX, RRY

Universal modular controller from the MTS family – MTS FlexTest Controller

MTS controllers are a reliable, valuable solution to current and future needs. They enable the sharing of test equipment; they are easily configurable to the needs of a wide range of tests and they can be extended for future tests.

Our laboratory is equipped with the following MTS controllers

• MTS FlexTest 60 – 8 channels
• MTS FlexTest 60 – 3 channels
• MTS FlexTest SE – 1 channel
• MTS FlexTest II CTC – 4 channels

Type approval of ball hitches and class A50-X towbars

The service comprises:

• Checking the dimensions indicated in Annex 5, p. 1.1. of the Regulation,
• Checking the surface roughness of the tow ball (smoothness class) specified in Annex 5, p. 1.1. of the Regulation,
• Checking the fatigue strength according to the requirements given in Annex 6 (points 2 and 3) of the Regulation,
• Checking the center of the hitch ball in relation to the car and the road surface as well as the free space around the hitch ball, according to the requirements of clause 1.1. Annex 7 of the Regulation,
• Issue of documents enabling the certificate of approval for the tested hitch or towing hook to be obtained.