3 reasons why stress analysis tests result in better cable shapes

3 reasons why stress analysis tests result in better cable shapes What is a stress analysis test?

To summarize it to the point of oversimplification, a stress analysis test is a computer simulation of the effects of various stress factors on a design to see what would happen. The specific type of test that Marlin Steel engineers use today is called Finite Element Analysis (FEA).

Autodesk, the maker of the FEA software that Marlin uses, defines FEA as "a computerized method to predict how a product reacts to real-world forces, vibration, heat, fluid flow and other physical effects."

Basically, FEA breaks a design into thousands of different pieces (the "finite" elements) and measures the overall impact of different types of stress on each over time.

There are several advantages to using FEA stress tests on physical prototype tests, which include: Faster test speed (minutes or hours instead of weeks or months).

Reduction of expenses due to the ability to test designs without having to use tools for a physical prototype.

Ability to simulate years or decades of use, which increases the thoroughness of the tests.

How do stress analysis tests result in better wire forms?

So how does a test method that takes only a few moments to complete and can simulate decades of use result in better wiring ways? Here are some reasons why stress analysis tests help ensure a better overall design for custom cabling forms: Prevent designers from making assumptions. One of the most dangerous things for any custom basket design is that the designer makes assumptions without checking them. Stress test designs help ensure that the design can withstand the stresses that designers could assume are right, and detect problems that designers can not anticipate.

Ensures more complete tests than prototype tests. It is a natural assumption that testing a physical prototype would be the most complete test for the design of a basket, but the ability of virtual tests to simulate years of use makes it more complete in the long term. After all, a physical prototype test can only last long before it starts to delay production. The ability of FEA software to verify years of stress in a basket in minutes helps discover problems that only appear after months of use.

It allows a faster iteration of the design. Because many custom designs must be completed in a tight schedule, delays in creating physical prototypes can lead to the reduction of corners; A design can get one or two new iterations to address the obvious problems detected during physical prototype testing.

Because FEA is completed in minutes, it is possible to go from one or two design iterations to dozens of design iterations in a fraction of the time. This helps ensure that the design of the final product is as polished as possible.

With only being relatively fast and easy to perform, stress analysis tests help ensure a better overall quality for custom wire forms. Being able to complete the tests quickly means that more iterations of design can be completed, which means there are more opportunities to polish the design and make it as good as possible for a specific application.

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