Combining test and simulation to tackle the challenges derived from boundary conditions mismatches in environmental testing

Recent research stressed out the limitations of current practices on component level environmental vibration testing. These limitations are typically associated with non-realistic excitation mechanisms and the mechanical impedance mismatch due to differences between the operational and the test boundary conditions. General concern is that the real failure modes of the component are not correctly replicated, and more information might be needed to define a representative test practice. Does the current testing practice provide sufficient information? Is there a way to overcome the impedance mismatch between operational conditions and the test configuration by means of simulations and adequate control strategy for environmental tests? This work presents recent results from an intensive test campaign performed on the Box Assembly with Removable Component (BARC). Limitations of state-of-the-art random vibration testing techniques are investigated and Multiple-Input Multiple-Output Random control strategies are combined with simulation tools to find potential research directions to overcome the limitations. The final goal intends to tackle a rationale, rather than a single specific solution, to assess the design of a testing methodology leading to structural responses which are more representative of the operational environment in terms of potential failure mechanisms.