Proper tightening of fasteners is critical in manufacturing and maintenance. Under-torqued hardware can vibrate loose, failing prematurely. Overtorqued bolts strip threads and damage parts. This results in leaky gaskets, electrical shorts, or complete mechanical breakdowns. Both torque testers and torque wrenches allow technicians to apply optimal torque, preventing these problems.
What is Torque?
Torque measures the amount of rotating force applied when tightening a fastener. It’s typically specified in Newton-meters (Nm) or foot-pounds (ft-lbs). Torque relates to the tension or stretch inside the bolt shank. As torque increases, so does the clamping force holding mating components together.
Each type of hardware – grades, lengths, diameters – requires a certain range of torque based on the materials, engineering principles, and product specifications. For example, an M6 socket cap screw may need 2-3 Nm while an M12 engine bolt gets torqued to 35-40 Nm.
Why Proper Torque Matters
Fasteners must be tightened to within their recommended torque range:
- Too loose – Components work loose over time from vibration or shock loads. This leads to damage from movement, leaks, electrical disconnects, or hardware backing out and jamming machinery.
- Too tight – Beyond the optimum level crushes gaskets, overstresses threads, or even cracks parts. Stripped threads mean rework to chase or replace fasteners.
- Just right – When fasteners get torqued properly as engineered, the assembly performs reliably throughout its service lifetime as designed.
Manual and pneumatic tools make it easy to under or over tighten without realized it as technicians “feel” for what seems snug. That’s why every technician needs torque instruments.
Torque Testers Validate Tightening
Torque testers measure just how much torque is being applied during tightening. There are several types:
- Dial torque testers look like a standard socket wrench but with a marked dial that indicates torque values in real-time similar to a fishing scale. The user tightens until the dial reads the target range.
- Digital torque testers show readings on a display. Advanced electronic versions store results and even plot torque over time. Some digitals emit alerts when spec is reached.
- Click type torque wrenches make an audible click when a preset torque level is met during tightening. The technician then knows to stop applying more rotational force.
Whatever style used, periodically testing torque confirms hardware gets assembled to OEM specs. It also aids troubleshooting loose components or threads during maintenance.
Torque Wrenches Tighten Precisely
While torque testers measure torque already applied, torque wrenches tighten fasteners to a preset value. These come in ratcheting, electric, pneumatic, and hydraulic formats. Dial, digital, and click type wrenches covered previously also tighten yet serve dual purposes.
Torque wrenches eliminate over or under tightening by controlling the torsional force. The amount of torque is usually adjustable. For example, a technician would set a torque wrench to 3 Nm then begin tightening a screw. At exactly 3 Nm of rotational resistance, the wrench clutch mechanism slips so not to exceed what’s calibrated.
Today’s torque wrenches offer +/- 3% or better accuracy. By always using a quality torque wrench for reassembly, technicians avoid overstress damage and create uniform tightness of multiple fasteners in an application.
Why Every Technician Needs Both
With only a manual wrench, ratchet, or impact gun, there’s no actual indication if proper torque was applied. Each tech would tighten based feel leading to vast variability. Maybe this time it felt a little tighter so more muscle was used. Perhaps wrench grip wasn’t quite the same producing different forces. And fatigue plays a role diminishing torque consistency over a work shift.
Conversely, just having a torque testing meter alone still allows inconsistencies when initially driving hardware down. One tech naturally may tighten more aggressively while another slowly ramps up force as they “feel it out.”
But by combining a preset torque wrench for the actual tightening along with intermittent torque testing to validate specs were hit, technicians can confirm proper and uniform fastener tensioning.
Using both tools in concert improves quality, safety, and reliability:
Benefits of a Torque Wrench
• Applies consistent torque assembly-to-assembly
- Prevents overtightening damage
- Allows documentation for audits
- Facilitates precision on small fasteners
Benefits of a Torque Tester
- Confirms target torque spec was achieved
- Provides actual verification for technicians
- Allows historical data trending over time
- Troubleshoots loose components
With torque instruments, there’s no guessing, feeling, or estimation hoping hardware was installed correctly. Physically measuring torque confirms optimal clamping force was reached, ensuring an assembly stands the test of time.
Why Choose Flexible Assembly?
Flexible Assembly offers comprehensive torque testing services so manufacturing and repair facilities can validate proper tensioning. Our expert metrologists conduct onsite audits or thorough evaluations in our torque testing lab.
Onsite Torque Testing
We dispatch seasoned technicians with the latest torque analyzer equipment to sample fasteners right on your production line, machinery, vehicles or anywhere needed. Testing is performed non-destructively with no disassembly required. You gain rapid insight into the current state of your hardware including:
- Assembly Variability
- Specification Conformance
- Under/Over Tightening
- Loose Components
Lab-Based Torque Analysis
For offsite torque testing with extensive data analysis, clients ship us samples from the application in question. We extensively test and measure per an agreed testing plan to diagnose torque issues. The benefit over basic handheld analyzers is running large sample sizes from multiple locations in the assembly. We deliver a detailed report that:
- Quantifies Variability
- Charts Trends
- Identifies Root Causes
- Recommends Solutions
Our expertise goes beyond metrology equipment to include statistical analysis that helps detect patterns that may escape visual inspections. Discover exactly where torque inconsistencies originate so they can be permanently eliminated.
Trust Flexible Assembly for All Your Torque Validation Needs
Rely on our torque testing specialists to validate your assembly procedures, maintenance programs, tool performance or quality control methods. We provide speedy feedback on the current state of hardware along with data-driven recommendations to optimize torque consistency moving forward. See why leading manufacturers trust Flexible Assembly for critical torque testing.
