Igniting Momentum through Insight and Input
WCS Industries’ team is enthusiastic and experienced when it comes to mechanical design and analysis. We know how important it is to have momentum in a project. It comes through a combination of consensus, small successes that build on each other, and good chemistry. The best ideas and the best results spark from that momentum. That’s the kind of engineering design and analysis partner we want to be for you.
WCS Industries engineers will perform a Process Analysis on your part to determine the optimal manufacturing strategy. Based on the quantity, component geometries, performance and cost objectives, our engineers will develop a process that best fits your needs for cost reduction and quality.
Evaluating Design and Analysis of Mechanical Components
We’re going to ask you questions like:
- What are you doing with the component?
- What is the end part?
- What is the end application?
We typically start the mechanical process analysis and design process by analyzing your application and requirements. When reviewing springs, we’ll take into consideration the cycle life, functional tolerances on loads, rates, and both outside and inside diameters. When reviewing cold-headed and machined parts, strength of material, field failure rate and the optimal blend of manufacturing processes are all taken into account. Hardness, cleanliness and dimensionality of certain components can also be factors to weigh.
Our mechanical testing services are designed to ensure the safety and effectiveness of any final product and components based on the performance and reliability of parts. Once we complete the initial analysis, we then evaluate specific details of tensile mechanical properties, including elasticity, strain, yield strength and more. These component performance testing steps determine effectiveness and reliability under a range of operating scenarios with different forces and other factors applied.
In addition to component performance testing, our mechanical testing services are critical in determining component failure thresholds or a number of failure conditions, including unacceptable deformation, fracture and wear. In addition to ensuring the quality and safety of components and products, failure analysis helps to create a more efficient product design process, getting you from concept to workable design more quickly and cost effectively.
WCS Industries component performance testing includes quality assurance data for scientific and engineering functions including tensile testing services, mechanical properties testing, mechanical life cycle testing and more.
After review, we’ll recommend our solution – including the proper material and finish. WCS Industries also has the ability to reverse engineer customer products and provide the dimensions needed to create a drawing or blue print. When applicable, our component design review is aided by the use of appropriate software [for example, spring design software ASD7].
Mechanical Properties Testing
WCS Industries offers a range of mechanical properties testing to support your product design, development and production processes. These testing services are especially useful during the design stage, providing deep insight into the performance characteristics of the product or component under varying operating conditions, from normal duty to more extreme scenarios. These test results help designers and engineers to determine whether a part will be able to perform to spec in the intended application and can help to identify potential failure scenarios. Testing services can also help reverse engineer parts for design enhancement. Here, we will examine some of the most common tests in use.
Fatigue testing: This type of test measures the effect of repeated or sustained mechanical strain on a component, identifying potential vulnerabilities for deformation, damage or other failure scenarios. Fatigue is generally accepted as one of the more common failure states, so this test can be extremely effective in preventing these potentially dangerous conditions. Fatigue testing typically includes torsional, rotational, shear, proof load and other types of tests.
Tensile strength test: In a tensile test, a component is placed under tensile stress (essentially, pulling it in opposite directions) to measure the maximum amount it can handle before failure. There are a number of different types of tensile stress conditions, including axial, weld, wedge, casting and elevated temperature tensile scenarios. It is important to test for any condition that is expected to occur during operation in order to identify the proper operating ranges for the component so that it does not fail.
Compression testing: Most frequently used with compression springs, this type of test measures the performance and integrity of a component when a compressing force is applied.
Other Testing is Done Using an Assortment of In-House Equipment, Including:
- Keyence I.M. System
- Optical Comparator
- Larson Flash 11Tester
- Dial Calipers
- Pin Gages
- SAS LST5000-PC Life Cycle Tester
- Six Test Stations
- Max Total Load (1,080 lbs)
- Max Total Load per Channel (180 lbs)
- Max Cycle Test Speed of 25 HZ (90,000/hr)
- Max Stroke 2.36″