Stress Testing 101

Stress testing is one of the most common use cases in test and measurement. It evaluates the structural integrity of objects and equipment, often pushing them to their limits. This type of testing helps identify design weaknesses or flaws, ensuring that products and components can withstand the stresses they’ll encounter in real-world use.

Stress tests examine performance data and measure the tested object’s reliability, durability, and ultimate strength.

Four specifications need to be defined in the stress test application before choosing a sensor: mechanical dimensions and mounting, electrical output and excitation, environmental temperature, plus performance accuracy requirements. Choosing load cells with verifiable calibration history reinforces the reliability of the stress test results.

The quality and accuracy of precise measurement devices are essential for stress testing. Interface load cells are a prime example of such tools, performing a fundamental part in research, design, and manufacturing. Interface load cells are engineered to deliver accurate force measurements, even under extreme conditions, making them indispensable in stress testing applications. Read Load Cells Built for Stress Testing.

Types of Stress Tests Using Interface Solutions

Interface load cells are used in a wide variety of stress tests, including:

• Material tests: Evaluating the strength and properties of materials
• Destructive and failure tests: Pushing components to their breaking point to understand their limits
• Ultimate tensile strength (UTS) tests: Determining the maximum stress a material can withstand before breaking
• Stress-strain curve tests: Analyzing the relationship between stress and strain in a material
• Elasticity tests: Measuring a material’s ability to deform under stress and return to its original shape
• Fatigue tests: Examining a material’s behavior under repeated loading and unloading cycles
• Cycle tests: Assessing a component’s performance under cyclic loading conditions
• Shear tests: Evaluating a material’s resistance to forces that cause one part of a material to slide past another part
• Bending tests: Analyzing a material’s behavior when subjected to bending forces
• Flexural tests: Measuring a material’s ability to resist deformation under bending loads
• Torsion tests: Evaluating a material’s resistance to twisting forces
• Environmental condition tests: Examining a component’s performance under various environmental conditions

Popular Interface Load Cells Used in Stress Testing

Our fatigue-rated load cells are commonly found in testing machines and stands used in stress testing. These precision load cells are engineered to withstand up to 100 million fully reversed load cells and have up to 300% overload ratings in tension and compression modes.

As noted in our Interface Load Cell Field Guide, not all manufacturers adhere strictly to the stringent discipline necessary to produce true fatigue-rated load cells consistently. By contrast, the history of Interface Low b cells shows a zero return rate due to fatigue failure for fatigue-rated cells used within ratings.

• 1000 Fatigue-Rated LowProfile® Load Cell: Ideal for applications requiring high accuracy and fatigue resistance
• 1000 High Capacity Fatigue-Rated LowProfile® Load Cell: Designed for high-capacity stress testing applications
• 1208 Flange Standard Precision LowProfile® Load Cell: Offers high accuracy and a compact design
• SML Low Height S-Type Load Cells: Suitable for applications with limited space
• WMCFP Overload Protected Sealed Stainless Steel Miniature Load Cell: Provides overload protection and a hermetically sealed design
• SSB Sealed Beam Load Cells: Offers high accuracy and a wide capacity range
• AT103 Axial Torsion Force and Torque Transducers: Measures both axial force and torque

Choosing the Right Load Cell for Stress Testing

Selecting the appropriate load cell requires careful consideration of several factors, starting with mechanical dimensions and mounting. The key is ensuring it is compatible with the testing setup based on your frame or test machine. The Load Cell Selection Guide is a great place to start.

The specific load cell chosen will depend on the stress test’s requirements, such as the force range, direction of loading, and desired accuracy. You must define the measurement ranges’ capacity in the stress testing plan. What is your plan for overload capacity? What is the cycle count? These parameters will help you select the load cell.

How will you use the data output? It is important to match the load cell’s output signal to the data acquisition system or specific instrumentation device. Use our Interface Instrumentation Selection Guide.

Interface load cells provide accurate and reliable force measurements, enabling engineers to gain valuable insights into the structural integrity of materials and components. This information is critical for designing safe and durable products that can withstand the rigors of real-world use.