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Mechanical Shock Test
Mechanical shock testing is a critical evaluation method used to determine a product’s ability to withstand sudden and high-magnitude accelerations. These shocks typically occur along a single axis—either vertically (with or against gravity) or horizontally—and simulate abrupt motion changes the product may experience during its lifecycle. The objective of the test is to assess both the structural durability and functional reliability of the device or component under high-impact conditions.
This type of testing is essential for identifying potential design weaknesses, ensuring mechanical integrity, and verifying that the product can endure real-world mechanical stresses without experiencing performance degradation, structural damage, or failure. It also provides valuable data on how well fasteners, joints, and internal components resist loosening or misalignment under sudden dynamic loads.
Applications of Mechanical Shock Testing
Mechanical shock testing is widely used across various industries, including aerospace, automotive, defence, consumer electronics, and industrial equipment. Common scenarios simulated by shock testing include:
- Drops and impacts during product handling and manual operations
- Vibrations and shocks experienced during transportation and shipping
- Sudden mechanical disturbances from operational use or external forces
- Explosive or ballistic impacts (in specialized military or aerospace contexts)
Test Configuration & Monitoring
During mechanical shock testing:
- The unit under test (DUT) is mounted on a shock test table or fixture, ensuring rigid coupling to prevent test anomalies.
- Controlled shock pulses are generated using a drop tower, shock machine, or pneumatic actuator.
- High-speed sensors and data acquisition systems monitor key parameters including acceleration, velocity change (Δv), and mechanical response.
- Visual inspection and functional testing may be conducted before and after each shock event to identify physical damage or performance issues.
Test Parameters
The following shock conditions are used to evaluate devices weighing less than 4 kilograms:
- 50g, 11ms – A moderate pulse duration used to simulate drop or impact events typical of consumer or portable devices.
- 50g, 6ms – A shorter pulse duration representing more abrupt impacts, suitable for fragile electronics or precision assemblies.
- 75g, 6ms – A higher-g shock with a fast rise time, used to test ruggedized components or those expected to experience severe shock environments.
Note: The term “g” refers to gravitational acceleration (9.81 m/s²), and “ms” represents milliseconds of pulse duration. Shorter pulse durations typically impart greater stress to the structure due to faster energy transfer.
Outcome Evaluation
After each shock pulse, the unit is examined for:
- Physical damage (cracks, deformation, dislodged components)
- Mechanical failure (loose fasteners, broken joints)
- Electrical or functional anomalies (circuit failure, intermittent operation)
- Deviation from specified tolerances or mechanical alignment
The results of this test help inform design improvements, qualify products for rugged environments, and validate compliance with regulatory or customer-specific shock resistance requirements.
Standards followed:
- IEC 60068-2-27
- MIL-STD-810H, Method 516.8
- MIL-STD-202, Method 213
- ISO 16750-3
- SAE J1455
- JSS 55555
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