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What are the Benefits of Merging With SCHENCK?

Test Devices by SCHENCK has built a strong reputation in the spin testing business. Since SCHENCK acquired Test Devices in 2017, we have been able to expand our services and improve our capabilities. We provide end-to-end services in spin testing, from one-off engineering testing to high-volume spin test processes for production. By combining our knowledge with SCHENCK’s global network, we can deliver broad expertise in both high speed spin testing and precision rotor balancing.

The financial backing and the support of SCHENCK grant us a competitive edge and give our clients access to services at a larger scale. Whether you require engineering consulting, test project management, balancing, or spin test services, we have the unique expertise to meet your needs.

The benefits of merging with SCHENCK include:

The Opening of a New Research Facility and Expanding Capabilities

Our Hudson site, Test Devices by SCHENCK, is now The North American Center of Excellence for testing. SCHENCK has heavily invested in this facility to upgrade its equipment, increase its capacity, and prepare for growing demands in spin testing resulting from the electrification in aircraft, vehicles, and other industries.

One of the recent and significant investments SCHENCK  has made is the addition of the new Centrio spin testing system at our Hudson facility. The system is the same one used by our Germany-based parent company SCHENCK ROTEC. Sharing the same system enhances the collaboration between the groups, the sharing of knowledge base and forms an excellent foundation to grow our testing capabilities for the betterment of our clients and their products.

What Is the Centrio Spin Testing System?

It is the “cutting-edge” spin testers in the world, giving us the capability to perform various advanced tests and data measurements to evaluate the customers’ rotors, especially for emerging e-mobility applications.

Being Able to Target New and Emerging Markets

Precision balancing and spin testing services also are essential elements in the production of EVs and other electric propulsion or mobility products. With the financial and technological backing from SCHENCK, a recognized global brand, Test Devices by SCHENCK is now positioned well to serve the growing needs of our customers beyond engineering testing. We offer some of the innovative and dependable solutions for customers with:

• Mass production automotive parts
• Large-scale production aerospace components
• eVTOLs such as drones and air taxis

SCHENCK has a deep customer base in both the automotive and aerospace sectors. We offer innovative testing and production support services with the highest standard of process integrity and quality. SCHENCK is very familiar with and equipped to meet the rigorous pace of mass-production work required in the automotive industry.

A One-Stop-Shop Facility

Test Devices by SCHENCK is dedicated to delivering top-quality products and services that meet or exceed customer requirements. We achieve this through continuous process and product innovation, ongoing improvements of our quality management system, and compliance with ISO9001 and AS9100 standards.

As your one-stop shop for engineering testing and outsourced production hub, we offer balancing, spin testing, and semi-finished machining services. We are equipped to handle all your needs from one-off pilot projects to managing your outsourced manufacturing operations.

See How Test Devices Can Help Your Organization Today

Turn to Test Devices by SCHENCK today for expert testing processes and more. Through support from our parent company SCHENCK USA, we offer a comprehensive range of spin testing services for the automotive, aviation, and transportation industries. Contact us today to learn more.

Intro to Low-Cycle Fatigue Testing for Electric Motors

Regarding material and machine components, the term “fatigue” refers to cracking or fracturing in an object caused by stresses that are within its operational envelop, and often within its elastic range. These cracks and fractures grow, and they can eventually lead to a failure of the component and damage or destruction to the greater assembly if left untreated.

Fatigue testing is a testing procedure used to determine the fatigue strength and life of a component. It is commonly utilized to identify potential areas of concern in a design. Test operations can be classified into two categories: low-cycle and high-cycle (LCF and HCF). The former involves subjecting the component to the fluctuating loads, typically from the machine’s operational cycles, while the latter involves subjecting the component to higher frequency, typically from a vibratory load related to structural resonance.

Why Is Low-Cycle Fatigue Testing Important?

High-speed rotating components (e.g., centrifuges, engine rotors, fans, impellers, etc.) regularly experience stresses that can lead to fatigue damage and, eventually, a failure. Since failure can damage equipment and endanger operators, it is vital to take measures to prevent it and, if that is impossible, mitigate the consequences.

Low-cycle fatigue testing (LCF) simulates the operational cycle of a machine. The LCF test is used to verify that a component is durable enough to withstand the use in the intended application over the intended duration of its operational life, so users can trust them and reliably operate the machine. Additionally, it could help manufacturers identify and resolve potential premature failure before the part or product goes into full production.

Low-Cycle Fatigue Testing Applications for Electric Motors

Nascent high-speed/high-performance electric motors, ones used in EVs, undergo low-cycle fatigue testing. These tests are necessary for a number of reasons, including:

• Testing new designs
• New materials
• Validating and tuning numerical models and component life prediction methods

In addition to electric motors, many other rotating components also undergo fatigue testing, such as:

• Centrifuge or compressor rotors
• Flywheels (including flywheels for energy storage)
• High-speed fans
• Industrial gas turbine rotors
• Jet engine rotors
• Rocket pumps
• Turbochargers

Advantages of Low-Cycle Fatigue Testing for Electric Motors

Fatigue test data enables electric motor manufacturers to understand the durability limit of the motor rotors, develop a dependable product life model to define appropriate product servicing life as well as establish a maintenance service schedule – the goal is to prevent any unexpected failure in the service life of the machine. Additionally, the data allows engineers to proactively plan for design improvements and modifications.

Low-Cycle Fatigue Testing Solutions From Test Devices by SCHENCK

Test Devices offers low-cycle fatigue spin testing services to customers working with high-speed rotating components in demanding applications. By choosing to work with us, you benefit from:

• Better Productivity: Our spin pits and test facility are designed to test through a component’s complete speed range and contain high-energy failures.
• Schedule: Our drive system offers the fastest acceleration and deceleration cycles for short testing schedules. Use of Test Devices’ patented Real-time Crack Detection System (RT_CDS) allows customers to expedite the schedule via reducing the need for interim inspections. Also, RT-CDS has proven its high dependability in halting the LCF test by detecting the onset of crack initiation before rotor failure, which saves customers from the need for time-consuming failure investigation work.
• Quality: Test Devices audits LCF cycle data to ensure the accuracy of the test and the integrity of the data. Our testing operation also conforms to AS9100 Aerospace standards.

To learn more about low-cycle fatigue testing or our testing capabilities, contact us today.

A Comprehensive Guide on CNC Machining

Computer numerical control (CNC) machining has proven itself an ideal method for mass producing metal and plastic parts. Even as other manufacturing methods like 3D printing have gained prominence in recent years, CNC machining has remained one of the most popular choices for a wide variety of fabrication needs. The aerospace sector relies heavily on CNC machining for the production of complex and mission-critical parts and components.

By leveraging the precision and automation of computerized control, CNC machining allows for the creation of intricate and accurate designs. In the past, manual machining processes relied on highly trained and skilled human operators to control the machinery. While some machine shops still use skilled machinists for prototypes, small-volume orders, or parts where repeatability or tolerances aren’t important, CNC machining has virtually eliminated the risk of human error in many manufacturing operations. Advanced programming regulates precise cutting patterns to ensure part-to-part uniformity and reliable adherence to tight tolerances.

What is CNC Machining?

CNC machining is a modern manufacturing process that takes in specific programmed instructions and uses that information to direct tooling as it cuts into the workpiece. CNC machining is not limited to one tool or piece of machinery. A spindle holds numerous tools, and CNC machines can often use multiple tools simultaneously from different angles. The term “numerical control” simply refers to the automated control of a machining process. The most common computer language for CNC machines is called G-code, though another language known as M-code is also sometimes used.

How Does CNC Machining Work?

To use a CNC machine, a skilled professional must program the computer. Once the machine has been activated, it reads through the program and enacts each of the instructions, employing a variety of tools and fabrication processes along the way. The CNC machine will follow its program under the assumption that all tools have carried out their function flawlessly. Small mechanical margins of error still exist, especially when the CNC process involves simultaneous cuts or other complex instructions. By and large, however, well-maintained CNC machines reliably perform in accordance with their programming.

While numerical control machines of the past read instructions through punch cards, today’s CNC machines require advanced computer programming. Operators enter the instructions into a computer and save the file into the machine’s records, where it can then easily find and invoke the instructions over and over. While many technicians are familiar with G-code and M-code languages, machine shops most commonly use computer-aided manufacturing (CAM) software, which can turn a computer-aided design (CAD) drawing into usable instructions for CNC machinery. This type of software makes the operator’s job much easier.

What are the Common Types of CNC Machines?

Numerous types of CNC machinery exist, enabling machine shops and manufacturers to conduct an expansive range of automated machining processes. Some of the most common CNC machine types include:

• CNC mills. CNC milling machines can cut a wide variety of materials in multiple dimensions. Most milling machines include an X, Y, and Z axis, which allows for exceptional detail and complexity. Cutting-edge machines may include additional axes for further precision and detail.
• CNC turning centers/CNC lathes. These specialized manufacturing tools are ideal for creating parts with symmetry around a central axis, such as pipes and shafts. CNC technology gives lathes an added level of precision that can be used to create more intricate parts.
• Plasma cutters. Plasma cutters seamlessly slice through material by using electricity and compressed-air gas to form a plasma torch. Plasma cutting requires conductive material, so it is mostly used to cut conductive metals such as steel, copper, brass, or aluminum.
• Water jet cutters. Water jet cutters create an intense stream of water that cuts through tough materials. Adding abrasives to the water stream facilities cutting of harder materials, such granite and titanium.

What are Some Popular Machining Techniques?

With many CNC machining processes available, it can be difficult to determine which ones to use for a specific project. While there is some overlap, most machining methods lend themselves to specific project or design needs. Here are some of the most popular and versatile CNC machining techniques:

• Roughing and semi-finish machining. These processes get most of the way to the final product, while leaving some excess material on the outside for fine-tuning by more precise machinery. Semi-finish machining reveals the final part geometry, but only strips the material within about 0.05” of the target dimensions. Also called roughing or rough machining, this process often uses CNC machinery to produce high volumes of roughed parts ready for final machining.
• Turning. Turning is one of the oldest manufacturing processes, but modern CNC lathes use advanced tooling and precision control to create highly accurate cylindrical parts with numerous features. As the workpiece rotates at high speeds, cutting tools move along the length of the piece to cut away material. More advanced turning centers can conduct additional processes, such as drilling holes.
• Milling. Milling holds the piece steady while a spindle with various cutting tools rotates around it, making precise cuts in accordance with the programmed instructions. Although the workpiece is mainly held horizontally, the cutting tool functions in the X, Y and Z directions. Four-axis and five-axis CNC milling machines have become increasingly common in recent years, offering further precision, speed, and complexity.
• Solid Sink EDM. Unlike the other processes, which all involve direct contact between tools and the target surface, solid sink electro-discharge machining (EDM) uses a an electrode that releases a powerful discharge that forces material to strip away from the metal surface. The material must be immersed in a dielectric fluid during the manufacturing process, and the electrode requires frequent replacement.

What are the Benefits of Machining with Test Devices?

At Test Devices by SCHENCK, our skilled and experienced staff brings extensive expertise to the manufacture of safety-critical rotating components made from challenging aerospace alloys. With a great deal of experience creating or adhering to the frozen manufacturing processes used by original equipment manufacturers (OEMs) in the aerospace sector, allowing us to guarantee a high rate of repeatability across each production run.

Test Devices by SCHENCK has become a premier provider of precision machining services for aerospace OEMs. We serve a customer base that accepts nothing less than the highest levels of accuracy, quality, and compliance with industry standards. Our manufacturing operations operate in strict compliance to AS9100/ISO 9100 quality management standards.

All our customers know we can respond and adapt quickly to project changes with minimal impact on production and delivery schedules. All of our teams, including machining, spin testing, balancing, and logistics operate in unison to provide end-to-end efficiency on every project.

For more information about Test Devices by SCHENCK and our machining capabilities for the aerospace sector, please contact us today.

Why Partner With Test Devices for Your Overspeed Spin Testing Needs?

Spin testing is a critical step in the manufacture of rotating components. While some original equipment manufacturers (OEM) may have the resources to perform these testing operations in-house, many do not. As such, they have to outsource these operations to a third-party spin testing service provider. Unfortunately, this option increases the potential for tight timelines or production delays as some service providers have long turnaround times (three or more weeks) even when two weeks or less is possible. These extended estimates can typically be attributed to a lack of communication between the client and provider, which, in addition to introducing uncertainty about when parts will be delivered, reduces the likelihood of a return customer.

We reduce lead times and costs associated with overspeed spin testing.

You can improve your product build and delivery efficiency by reducing process lead times. However, efficiency is not the only factor on which you should focus. You should also emphasize reliability, which influences whether you can consistently meet your customers’ order requirements  in a timely manner.

Equipped with extensive spin testing experience, we have what it takes to offer efficient and reliable overspeed testing solutions. We have  to accommodate high test volumes. All work are carefully and quickly planned, tracked, and executed. In many cases, we can cut turnaround time by two or more weeks (a 33–66% reduction in lead time compared to our competitors), which makes it easier for you to meet your product delivery timelines and positively affects your cash flow.

We have a dedicated service team.

In today’s manufacturing world, flexibility and responsiveness are essential. Regarding OEMs, this means ensuring on-time delivery and remaining aware of and being able to respond to changing demands. Having a reliable production and supply chain is key to achieving these goals so you can stay ahead of the competition and retain your customers.

Our dedicated  service team is ready to help keep you on track. We quickly review and execute spin testing requests, so your customers do not have to worry about delayed shipments or long wait times between order placement and fulfillment. This reliability can help improve your customer retention rates, leading to a larger customer base and expanded capabilities over time.

We are ISO9001/AS9100 certified.

We are committed to providing high-quality spin testing services and products that meet or exceed our clients’ requirements. This dedication to quality is reflected by our maintenance and adherence to an AS9100/ISO 9001 certified quality management system. Our quality management system is updated on an annual basis and subjected to regular internal and external audits to ensure its robustness. We also employ certified inspectors to dimensionally inspect 100% of all hardware manufactured from drawings.

Connect With the Experts at Test Devices Today

At Test Devices, we are a trusted spin testing  and service provider for leading OEMs in many industries. To learn more about our products and services or partner with us for your overspeed testing needs, contact us or request a quote today.

The Commercial Space Economy Forecasts an Optimistic Future

With the recent manned mission of a US-made rocket, and advancements in reusable launch systems, commercial space is coming into the spotlight and showing an optimistic future.

The commercial space economy has been steadily growing in recent years for reasons ranging from financials to innovative breakthroughs in technology. Although the manned-mission is in the spotlight, in terms of segmentation of various commercial space activities, unmanned operation is forecasted to contribute a larger share of activity.

North America still leads the overall launch capability and is said to have the largest market share in the spacecraft industry. NASA’s renewed resolve in returning to the moon, and extending the reach of the manned mission to Mars, comes with a significant budget to accelerate the development of space technologies and the economy. Anticipating the future of space commerce, many entrepreneurs and pioneering companies are entering the new space race to find unique ways to provide the necessary services for this emerging industry – including the following:

Affordable Launch / Rocket technologies: Curbing the cost of launch is the foundation of making space accessible for commercial companies.

Satellite Internet / Communication: Most likely the development and deployment of communication technology is the most immediate opportunity for space businesses. Companies focused on improving the accessibility and the reach of wireless broadband and connectivity through satellites.

Asteroid / Moon Mining & Manufacturing in Space: The idea sounds like a science fiction story, but companies are exploring ways to extract water and rare minerals from asteroids, and the moon. Some of these companies are also involved in developing the manufacturing technologies required to build structures in orbit and on other planets.

Refueling Services: Gas stations in orbit? The capability to fuel/refuel spacecraft destined for long range target (Mars), as well as the satellites that are already in the earth’s orbit, is an essential part of space commerce and rapidly becoming a reality.

Cleaning up Space Debris: With all of the satellites and manmade machinery that we have launched and left in space, the Earth’s orbit is becoming cluttered – We need companies that can track and remove this “space junk” to avoid accidents and keep space accessible.

Space Tourism: Perhaps what most earth citizens are looking forward to the most is the ability to take a brief trip to space. Though ticket prices for space tourism are still astronomically expensive, these companies are developing ways to make it affordable and bring the space adventure to many of us.

Space Exploration / Colonization: This is probably the most popular and audacious goal amongst the leading space ventures. These companies are working on sending and settling humans and cargo beyond earth’s orbit, including the moon and mars in the near future.

Technology Advancements Driving an Optimistic Future 

Space entrepreneurs are exploring and pursuing ambitious goals such as colonizing other planets, mining asteroids, setting up space tourism, building manufacturing plants in orbit, as well as pursuing ways to further lower the cost of access to space – such as airplane-borne rocket and air-to-space launchers. It is clear that reusable rockets and space-age commercialization are today’s reality. Lower per-launch costs and miniaturization of payloads/satellites are opening new doors for non-aerospace and defense sectors, further demonstrating that commercial space is showing an optimistic future.

With reusable rocket technology advancements, the cost of launching a rocket has declined drastically to 33% of previous costs (from $200 million to $60 million). Morgan Stanley, a leading business analysis firm, predicts a potential launch cost of $5 million, in the near future. The global space industry is expected to generate $1.1 trillion in revenue by 2040, up from  $350 billion in 2019.

How Test Devices Contributes to the Commercial Space Economy?

We are the leading experts in high-speed rotor testing, manufacturing, and rotor balancing technologies, especially for aerospace applications. For decades Test Devices by Schenck, has been a dependable partner to many of the leading aerospace propulsion OMEs. Our capability in executing aerospace-grade engineering tests and managing outsourced manufacturing operations is only matched by our passion for sharing our customers’ success.

There are several operationally critical high-speed rotating parts in each rocket engine.  We both test and perform important operations in the overall component manufacturing processes. Test Devices currently performs production spin testing to satisfy NASA standard 5019 section 7.2.7 fracture critical rotating hardware.  Typical items that are associated with fracture critical rotation are turbine, Fuel pumps, and LOX impellers.

Partnering with us not only provides you with the benefits of our extensive experience and dedicated team, but you will also be working with a team that keeps quality, safety, and continuous improvement at the forefront of our business. Customers want to work with Test Devices because of our focused approach on the most demanding manufacturing requirements, whether it be spin testing, semi-finish machining, or other critical processes.

For more information or to get in touch, please contact us today.

Why Choose a Full Service Semi-Finish Manufacturer?

Full-Service Manufacturing: What Makes Us Unique?

Through our extensive knowledge and expertise in rough and semi-finish manufacturing, we are able to give our customers the highest quality rotating parts making us the industry leader in this category. While success in these areas does require a dedicated team, what makes Test Devices unique is our combination of experts with our suite of on-site resources. 

Other facilities can surely spin and shape products, but more importantly we are equipped with the best engineers, operators, and equipment that can handle the unexpected inevitable challenges that arise in machining. With our versatile staff and top of the line equipment, at Test Devices, we have the capabilities to execute:

• Designing
• Engineering
• Prototyping
• Machining
• High Speed Spin Testing
• CMM
• Balancing

The Attention You Deserve

Our staff is nothing short of thorough, detail oriented, and personable. In a fast-paced environment with changing schedules, specifications, delivery schedules, and rotating points-of-contact, we understand that change is inevitable, and we need to be able to work quickly and efficiently.

Where we stand out among the rest is our ability to adapt to our customer’s needs. We stay engaged in personal and frequent contact, ensuring that feedback is not missed and capturing our customer’s needs and any changes along the way. Our production management will ensure part shipments are made on a day to day basis, while continuing to develop and maintain relationships with our customers and meeting their demands. 

No matter how urgent the request, our customers know that at Test Devices we will respond quickly with actionable steps, as we understand these changes could have an effect on our manufacturing and delivery schedule. 

Experts on Materials

With our staff of highly trained experts, we cover a vast amount of knowledge when speaking about rough and semi finish machining of complex alloys and critical rotating parts. At Test Devices, we routinely provide finishing for the following:

• Heat-resistant super alloys
• High-nickel content aerospace superalloys
• Precision critical rotating components
• Parts within tolerances of (+-) 0.0005”
• High-precision geometric shapes from rough forgings

Our Proven Commitment

Driven by our commitment to provide high quality services and products and dedicated customer service, our expert staff will see any challenge to the finish line. 

After several years of successfully providing pre-finished parts to one of our customers, a major aerospace manufacturer, Test Devices experienced an increase in un-spinnable parts. After completing a detailed and thorough inspection of the machinery, our team was able to identify the problem which was determined to be a change in machining setup by the customer. We were then able to make the professional recommendation and solve the issue.

A second example involved an issue during spin testing for a leading manufacturer of centrifugal impellers. Similar to our first example, after years of successfully delivering parts to our client, we encountered an issue when we realized a handful of parts were unbalanced. After the inspection of the machinery, we were able to determine the issue at hand and successfully resolve it. 

Why You Should Choose Test Devices

Partnering with us not only provides you with the benefits of our extensive experience and dedicated team, but you will also be working with a team who keeps quality, safety, and continuous improvement at the forefront of our business. Customers want to work with TD because of our focused approach on the most demanding manufacturing requirements, whether it be spin testing, semi-finish machining, or other critical processes.

To read more about our entire rough and semi-finish machining services all under one roof, click here or on that picture to get your free copy of our eBook “Unparalleled Value: The Benefits of Our Rough & Semi-Finish Rotating Disk Machining Services now.