Load Envelopment: We capture the full range of loads for a component and envelope data from the various load cases and component locations to ensure we capture the full envelope the given part will see.Simplify Load Vectors: From the complete dataset, we derive load vectors—typically one or two channels—that reproduce the right stress relationship at the critical locations. For complex components such as knuckles and subframes, this can involve extensive FEA modelling to get it right.Local Stress Conversion & Cycle Selection: These simplified load vectors are then converted into local stress or strain values. Using rainflow and an appropriate damage model (parent metal, rubber, welds, castings etc.), we identify the critical cycles, considering both Low Cycle Fatigue (LCF), High Cycle Fatigue (HCF) and other factors such as surface finish.Back Conversion & Multi-Axial Verification: The selected cycles are converted back to loads, and we employ cloud plotting techniques to verify that the multiple channels accurately reproduce the correct multi-axial stress distribution.Proprietary Tools & Techniques: This highly iterative process is powered by Re:Test’s highly efficient proprietary tools and techniques, ensuring the final test protocol is an accurate simplification and acceleration of the complex real-world load environment.This is just one example of the types of work that Re:Test can provide. From Loads Development, through Analysis and Test, to Validation, we can support your team at every stage.
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