Vibration Testing for military compliance is a crucial aspect for products aiming to serve in military applications. To ensure that these products can endure a severe military environment, they must undergo rigorous testing at a state-of-the-art vibration testing lab. This process involves defining the environmental life cycle that the product will encounter and then developing and executing a qualification test plan based on specific military standards. Completing these tests and documenting them in a detailed report is integral to achieving military compliance.

Why Perform Military Compliance Vibration Testing?

Military compliance vibration testing is especially crucial for military products integrated into complex and costly systems, where failure can lead to significant consequences. The principle reasons for executing this testing include the following:

1. Ruggedizing Your Product:  Testing your product to a military standard vibration profile will ensure that it can withstand harsh vibration exposures that it would experience throughout its life cycle.
2. Evaluating Performance: Military compliance vibration testing ensures that items will perform properly under harsh vibration conditions.  If your component does not function properly, it could cause a failure of a complicated system. 
3. Reducing Maintenance and Preventing Field Failures:  A robust product will have less or no field failures, reduce downtime and maintenance which is critical for military applications. 

Focusing specifically on vibration testing for military compliance, this article delves into various military standards that are vital in evaluating a product’s durability and ruggedness. These include MIL-STD-167, MIL-STD-202, MIL-STD-750, MIL-STD-810, and MIL-STD-883, each with their specific testing methods for a range of environmental conditions including sinusoidal and random vibration testing.

• MIL-STD-167 Department of Defense Test Method Standard – Mechanical Vibrations of Shipboard Equipment
• MIL-STD-202 Department of Defense Test Method Standard for Electronic and Electrical Component Parts
• MIL-STD-750 Test Methods for Semiconductor Devices
• MIL-STD-810 Department of Defense Test Method Standard for Environmental Engineering Considerations and Laboratory Tests
• MIL-STD-883 Department of Defense Test Method Standard for Microcircuits

MIL-STD-167 applies to equipment installed on Navy ships with conventionally shafted propulsion.  MIL-STD-167-1 covers mechanical vibrations caused by unbalanced rotating components of Naval shipboard equipment.  MIL-STD-167-2 is for mechanical vibrations from reciprocating machinery and lateral, longitudinal vibrations of propulsion systems and shafting. 

MIL-STD-202 establishes uniform methods for testing electronic and electrical component parts.  MIL-STD-202 defines component parts to include capacitors, resistors, switches, relays, transformers, inductors, etc.  This standard is intended to apply only to small component parts, weighing less than 300 pounds or having a root mean square test voltage up to 50,000 volts. 

MIL-STD-750 is intended to apply only to testing semiconductor devices.  Semiconductor devices include such items as transistors, diodes, voltage regulators, rectifiers, tunnel diodes, and other related parts.

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MIL Standard 810 Testing: The DES Commitment

MIL-STD-810, known for its stringent requirements, is crucial for products intended for military use, and at DES, we ensure that these products meet and exceed these rigorous standards.

Our approach to MIL Standard 810 testing is comprehensive and meticulous. We understand that each product has its unique set of challenges and requirements. Therefore, our testing process is not just about meeting the basic compliance standards; it’s about thoroughly understanding the product’s lifecycle and the environmental stresses it will endure.

Our state-of-the-art facilities are equipped to conduct the methods under MIL-STD-810H, ensuring that we cover a wide range of environmental conditions. From high and low temperatures to shock and vibration, our tests are designed to mimic the harsh conditions that products will face in real-world military environments. This thorough testing not only ensures compliance but also aids in enhancing the product’s design and durability.

Choosing DES for MIL Standard 810 testing and all other military compliance testing means partnering with a team that values precision, quality, and customer satisfaction above all else. Our experience and expertise in this field make us a trusted partner for numerous manufacturers, from small component producers to large-scale military equipment manufacturers.

Contact Delserro Engineering Solutions today to learn more about our MIL Standard 810 testing services and how we can assist in bringing your products to the highest standards of military readiness and reliability.

MIL Standard 883: Advanced Testing for Microelectronics

As mentioned in the previous list, MIL-STD-883 is critical for the testing of microelectronics used in military applications. This Department of Defense Test Method Standard for Microcircuits is essential for ensuring that microelectronic devices can withstand the demanding conditions of military use. MIL-STD-883 encompasses a comprehensive suite of test procedures tailored to assess the robustness and reliability of various microelectronic devices, including monolithic, multichip, film, and hybrid microcircuits, as well as microcircuit arrays and their constituent elements.

The standard plays a pivotal role in validating the endurance of microelectronics in extreme environmental conditions. This includes evaluating their performance under conditions of extreme temperature, vibration, and other stress factors that are commonly encountered in military environments.

For manufacturers and designers of microelectronic devices, adhering to MIL-STD-883 is not just about compliance; it’s about guaranteeing the highest levels of performance and reliability of their products in some of the most challenging conditions. This is especially crucial given the increasing complexity and miniaturization of electronic components in military hardware.

Delserro Engineering Solutions (DES) provides comprehensive testing services to ensure compliance with MIL-STD-883. Our advanced testing capabilities help manufacturers navigate the complexities of MIL-STD-883, offering the assurance that their microelectronics meet all necessary military specifications. With our state-of-the-art facilities and technical expertise, we are equipped to handle the rigorous testing requirements of MIL-STD-883, delivering results that manufacturers can trust for their high-performance microelectronic products.

Vibration Testing Lab: Cutting-Edge Solutions by DES

At Delserro Engineering Solutions (DES), our state-of-the-art vibration testing lab is equipped to provide comprehensive solutions for military compliance. Understanding the criticality of these tests for military applications, we offer advanced testing procedures that replicate the exact conditions products will face in the field.

Moreover, DES recognizes the importance of customizing vibration testing to meet the specific requirements of each product and its intended use. Whether it’s testing for land and sea vehicles, aircraft, helicopters, or ground transport, we tailor our vibration testing procedures to ensure the most relevant and rigorous evaluation.

Our expertise extends beyond just executing standard tests. We work closely with our clients to develop comprehensive test plans that not only meet the required standards but also provide valuable insights into product performance and potential areas for enhancement. This approach helps in identifying and rectifying deficiencies early in the design process, saving time and costs, and ultimately leading to a more robust and reliable product.

With DES’s vibration testing lab, clients can expect not just testing, but a partnership that focuses on enhancing the quality and durability of their products. Reach out to us to discuss how we can assist in fulfilling your military vibration testing requirements with our cutting-edge solutions and expert guidance.

Contact DES today to discuss your vibration testing lab requirements.

If you want to learn more about vibration testing, please read these related blog articles:

MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

MIL-STD-810: Vibration Testing Category 12 – Fixed Wing Jet Aircraft

MIL-STD-810: Vibration Testing Category 15 – Aircraft Stores

MIL-STD-810: Vibration Testing Category 20 – Ground Vehicles – Ground Mobile

MIL-STD-810: Vibration Testing Category 24 – Minimum Integrity Tests (MIT)

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MIL-STD 810 is a Department of Defense Test Method Standard for environmental engineering considerations and laboratory tests.  It is the most popular Military specification used to conduct environmental testing of military products.  It exists so as to ensure that products used for defense-related purposes meet very specific requirements with regard to ruggedness, durability, and performance.  Given the fact that these products may be exposed to harsh or even extreme conditions, their reliability under stress is essential

MIL-STD 810 is jointly maintained by the Army, Navy, and Air Force, while being enforced by the Department of Defense.  There have been a number of iterations of MIL-STD 810, and the current version is MIL-STD 810H.  This military standard is periodically updated to reflect emerging technologies, as well as to amend any deficiencies which have become apparent with experience.  The updates are made by a MIL-STD 810 Working Group comprised of experts from the Army, Navy, Air Force and private industry.  

MIL-STD 810 is a standard which has now reached over 1,000 pages in length, and is comprised of three major sections: Environmental Engineering Program Guidelines, Laboratory Test Methods, and World Climatic Regions.  The second of these, the Laboratory Test Methods, is the one which many manufacturers focus on the most, because it’s the one which contains test procedures.

Purpose of Mil Std 810

The purpose of Mil-Std 810 is to ensure products will survive in harsh military applications.  Additionally, it helps achieve the objective of developing products that will perform adequately under the environmental conditions likely to be found throughout their life-cycle in the regions of intended use.

Part One’s, Environmental Engineering Program Guidelines, purpose is to describe management, engineering, and technical roles in the environmental design and testing process.  It focuses on the process of tailoring materiel design and test criteria to the specific environmental conditions an item is likely to encounter during its service life.

Part Two’s, Laboratory Test Methods, objective is to define test methods that can be consistently performed by any laboratory.  This section also defines requirements for equipment used to perform testing.  It contains environmental data and references, and identifies possible tailoring opportunities for the test methods.  Some methods afford a wide latitude for tailoring; while some have relatively few tailoring options.  There is also background information to help determine the appropriate level of tailoring.

Part Three, contains a compendium of climatic data from World Regions.  Its purpose is to provide climatic data to aid in the research, development, test, and evaluation of items used throughout their life cycles in various regions throughout the world.   

Product testing with MIL-STD 810

Products that are sold to the Military have to undergo extensive reliability testing, usually to a Military standard.  MIL-STD 810 is the most popular standard used for this application.   Testing must be conducted in specially equipped laboratories capable of subjecting products to harsh test conditions.  There are numerous types of tests which can be conducted on a given product, checking conditions such as low pressure, high & low temperatures, rain, sand or dust, vibration, shock, icing and freezing, acceleration, and acoustic noise.  The list of specific methods in MIL-STD 810 is as follows:

• Method 500  Low Pressure (Altitude)
• Method 501 High Temperature
• Method 502 Low Temperature
• Method 503 Temperature Shock
• Method 504 Contamination by Fluids
• Method 505 Solar Radiation (Sunshine)
• Method 506 Rain
• Method 507 Humidity
• Method 508 Fungus
• Method 509 Salt Fog
• Method 510.Sand and Dust
• Method 511 Explosive Atmosphere
• Method 512 Immersion
• Method 513 Acceleration
• Method 514 Vibration
• Method 515 Acoustic Noise
• Method 516.Shock
• Method 517 Pyroshock
• Method 518 Acidic Atmosphere
• Method 519 Gunfire Shock
• Method 520 Combined Environments, Temperature, Humidity, Vibration, and Altitude
• Method 521 Icing/Freezing Rain
• Method 522 Ballistic Shock
• Method 523 Vibro-Acoustic/Temperature
• Method 524 Freeze / Thaw
• Method 525 Time Waveform Replication
• Method 526 Rail Impact
• Method 527 Multi-Exciter
• Method 528 Mechanical Vibrations of Shipboard Equipment

Conclusion

Over the years, MIL-STD 810 has been developed as a means to ensure that products used by the armed forces perform optimally, even under extreme conditions such as might be encountered in harsh climates or under combat conditions.  Because these test conditions are so thorough, they have also been adopted by some civilian manufacturers who wish to claim that their products have been designed and engineered to the same exacting standards required by the Military. You can therefore expect that any product that is tested to MIL-STD-810 requirements will perform well, even when exposed to severe conditions.

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MIL-STD 810, Method 516, Shock Testing Overview

Shock testing according to Procedure I of MIL-STD 810, Method 516 is intended to test products while they are operating to see if any functional problems occur and to determine if they survive without damage.  The applied shocks usually represent those that may be encountered during operational service.  This article will focus on the shock test condition when measured field data is not available and the testing will use classical shock impulses.  The terminal peak sawtooth is the default classical shock pulse to be used for this condition.  Figure 516.7-10 from MIL-STD-810 shows its shape and tolerance limits.  Table 516.7-IV contains the terminal peak sawtooth default test parameters for Procedure I -Functional Test.  In limited cases a half sine shock impulse is specified.  Its shape and tolerance limits are shown in Figure 516.7-12.

The product should be mounted to the machine or fixture as it would in normal use.  So, if it is bolted using a flange, then it should be attached to a fixture using this flange with the same size and number of bolts.

The typical shock testing procedure is to first perform calibration shocks using a mass similar in size, weight and center of gravity (CG) of the product to be tested.  Most commonly a non-working mechanical product is used for this purpose.  Once the desired shock requirements are met with the calibration mass, the mass is removed and the product to be tested is installed on the shock test machine or fixture.  Since this is a functional shock, the product must be operating and monitored for anomalies.   Therefore, before the shock is applied, the product must be energized and the monitoring equipment should be operating.  After each shock, operation of the test item is verified and it is inspected for visual damage.

The most common requirement is to perform 3 shocks along both the positive and negative directions along 3 orthogonal axes.  This is a total of 6 directions and 18 shocks.  When setting up to perform shocks in each direction, calibration shocks with the mass simulant are performed first because the weight, CG and product response could require different settings on the shock machine.  The shocks are performed along both the positive and negative directions of each axis because classical shocks are single polarity.

For more information on Shock Testing or other testing services, contact DES or call 610.253.6637.

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Vibration Testing Articles

MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

MIL-STD-810: Vibration Testing Category 12 – Fixed Wing Jet Aircraft

MIL-STD-810: Vibration Testing Category 15 – Aircraft Stores

MIL-STD-810: Vibration Testing Category 20 – Ground Vehicles – Ground Mobile

Minimum Integrity Testing

MIL-STD-810 Method 514.7, Annex E offers alternative supplemental product vibration testing services. One of which is referred to as minimum integrity testing (MIT). The MIT can be used as a baseline test for materiel either in the early stages of product design or where environmental vibration is unknown. MIT is designed to provide reasonable assurance that materiel can withstand installation/removal, transportation, handling, etc. MIT cannot be used for qualification. Tailored test methods are preferred over MIT.

Figures 1 and 2 show the vibration profiles outlined for MIT in Method 514.7, Annex E. Figure 1 is a random vibration profile for general use, while Figure 2 is a sinusoidal vibration profile for helicopter material. They were not developed from application environments.

The material under test should be hard mounted to a fixture. These vibration tests should not be applied through vibration isolation. The MIT should not be applied to large material because unnecessarily high loads could be induced in mounting and chassis structures, while higher frequency vibrations at subassemblies are low. In cases where the material is large, the MIT should be applied to subassemblies. The maximum test weight of a materiel or subassembly should be approximately 36 kg (80 lb) when using MIT.

According to MIL-STD-810G w/Change 1, experience has shown that materiel that withstands these exposures typically functions satisfactorily in the field. Failure to pass an MIT does not imply that the materiel will fail in its service environment. Failure to function subsequent to exposure to an MIT test should serve as grounds to make an attempt to define the test environment and make an effort at developing a tailored test.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

MIL-STD-810: Vibration Testing Category 12 – Fixed Wing Jet Aircraft

MIL-STD-810: Vibration Testing Category 15 – Aircraft Stores

Category 20 of Method 514.7 Vibration testing details the vibration profile of ground mobile environments which features a broadband of random vibration with peaks and valleys.  The peaks and valleys represent a number of different factors including but not limited to differential road terrain, vehicle speed, structural characteristics and suspension.  For tracked vehicles, MIL-STD-810G recommends that testing use a random-on-random vibration strategy.  Figure 1 illustrates a representative plot of a tracked vehicle vibration profile.  The vibration test durations are determined from the Life Cycle Environment Profile.

To learn more about our vibration testing services, please feel free to contact us with your inquiry. Feel free to explore our site to learn about our full line of product testing services, and the product testing standards that we can help our clients with.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

MIL-STD-810: Vibration Testing Category 12 – Fixed Wing Jet Aircraft

Category 15 of Method 514.7 Vibration testing describes the different vibratory environments aircraft stores may experience in an aircraft.  Three environments are detailed in category 15; captive flight – external carriage, captive flight – internal carriage and free flight.

Captive flight – external carriage include stores carried externally on a jet aircraft.  The overall vibration profile arises from four sources; engine noise, in-flight aerodynamic turbulence, vibration transmitted through attaching structures and internal store vibration.  Engine noise is highest at the boundary layer of the exhaust jet plume.  At this point there is turbulence between the exhaust air and ambient air and is at its maximum during takeoff.  In-flight aerodynamic turbulence do not greatly affect overall store vibration, however, they may cause other structures such as tailfins to produce vibrations that are then transmitted to the store.  These vibrations, as it states in category 15 of method 514.7, are a “low frequency system” and are often characterized as buffet vibration, Figure 2.  “Buffet vibration is typically concentrated between 10 and 50 Hz” and “is dominated by store structural resonances.”  Finally stores are also susceptible to internal vibration from elements such as rotating machinery.

Captive flight – internal carriages generally don’t experience harsh vibration levels unless the bay is opened during flight.  “This event is referred to as a cavity resonance and results in high levels of turbulence inside the bay.”  This vibration is characterized as a wide band spectrum with high spikes across it.  Low frequency spikes (<100 Hz) are not expected to be of issue for most stores, however, high frequency spikes can be very dangerous.

Free flight vibration will typically be experienced by stores that are deployed from the aircraft.  Free flight vibration is comprised of engine noise vibration, onboard vibration and varying turbulence similar to that of captive flight.

Figure 1 below, shows the profile for store vibration exposure on jet aircrafts.  Figure 2 shows the vibration profile for buffet vibration response.  W0, W1 and W2 in Figures 1 and 2 are calculated from rather complicated tables and formulas within Category 15.  The vibration testing durations are determined from the Life Cycle Environment Profile.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

MIL-STD-810: Vibration Testing Category 8 – Aircraft – Propeller

Category 12 of Method 514.7 Vibration testing begins the operational vibration exposure section (Annex D) of Method 514.7 and defines the tests necessary for products to operate in and survive vibration environments.  Category 12 outlines the vibration environment for products installed in fixed wing jet aircrafts (except if said product is engine-mounted).  The vibration environment of installed products in fixed wing jet aircrafts is made up of 4 components; airframe structural response, jet noise and aerodynamically induced vibration, cavity noise induced vibration, material induced vibration.

Airframe structural response dynamics are from the response of flexible airframe structures to typical events such as take-off and landing impacts.  Jet noise and aerodynamically induced vibration are determined primarily by altitude and speed where jet noise dominates over subsonic speeds at lower altitudes and transonic speeds at higher altitudes.  Aerodynamically induced vibration typically dominates at transonic speeds at lower altitudes and supersonic speeds at any altitude.  Cavity noise induced vibration is caused by openings in the aircraft skin where external airflow is allowed to pass through.

As you can imagine, the fluctuating pressures produce turbulent airflow causing vibration to the surrounding parts.  Finally material induced vibration is any vibration that is created from surrounding product operation.  Examples are motors, pumps and gear boxes.

Figure 1 illustrates the typical vibration profile for products installed in fixed wing jet aircraft.  The parameters of the plot are calculated using equations outlined below in Table 1.  Typical test durations are 1 hour per axis for endurance testing or 5 to 10 minutes per axis to demonstrate that products will operate acceptably in these environments.

To learn how Delserro Engineering Solutions can help you test for exposure issues in your product through our vibration testing services, or our range of dynamic testing services, please contact us today.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

MIL-STD-810: Vibration Testing Category 7 – Aircraft – Jet

Category 8 of Method 514.7 simulates the vibration environment for cargo carried in propeller aircraft.  The vibration environment generated from propeller aircraft are dominated by high amplitude approximately sinusoidal spikes at propeller passage frequency and harmonics.  Lower level wide band random vibration is also present due to air flow over the aircraft.  Collectively, these phenomena are superimposed to create the vibration profile for cargo carried on propeller aircraft resulting in a Mixed Mode Vibration Test.

Figure 1 and Table 1 show the vibration profile for this environmental condition.  The test durations are obtained from the products life cycle environment or one hour per axis if the duration is unknown.

To learn more about our vibration testing services, please feel free to contact us with your inquiry. Feel free to explore our site to learn about our full line of product testing services, and the test standards that we can help our clients with.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

MIL-STD-810: Vibration Testing Category 9 – Aircraft – Helicopter

Category 7 of Method 514.7 Vibration testing simulates vibration conditions of cargo in jet aircraft.  These vibrations are broadband random.  Typically the maximum vibration levels produced are caused by the exhaust noise generated during takeoff.  Vibration during normal flight is substantially less.  Figure 1 and Table 1 detail the Acceleration Spectral Density (ASD) and frequency levels of various aircrafts and the vibration exposure of cargo carried on those respective aircrafts during takeoff.  The General Exposure curve can be used when the specific aircraft is no known.

The test duration is 1 minute per takeoff times the number of takeoffs the product may see in its lifetime.

To learn more about our vibration testing services, please feel free to contact us with your inquiry. Feel free to explore our site to learn about our full line of product testing services, and the test standards that we can help our clients with.

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MIL-STD-810 Vibration Testing Overview

MIL-STD-810: Vibration Testing Category 4 – Truck/Trailer – Secured Cargo

Procedure I (General Vibration), Category 9 of Method 514.7 Vibration testing details the vibration profile of cargo carried in helicopters.  This vibration profile is unique because it superimposes strong narrowband peaks of sinusoidal vibration caused by rotating components such as the main or tail rotors, over low-level wideband random vibration caused by aerodynamic flow.  This vibration profile is generally referred to as Sine on Random Vibration Testing.  Figure 1 outlines the typical vibration profile and the variables which are determined based upon the type of helicopter as well as the location on the helicopter where your product will be used or stored.  Tables 1 and 2 define the equations and properties used to determine the variables used in the Figure 1 plot.

Default test duration is 4 hours in each of 3 orthogonal axes for a total test time of 12 hours.  This test duration represents a 2500-hour operational life.  The levels in Figure 1, Tables 1 and 2 are intended to envelope worst-case environments, and have been aggressively compressed in time from 2500 hours to 4 hours.

Figure 1. Figure 514.7C-9 from MIL-STD-810G w/ Change 1 – Helicopter Vibration Profile (Sine over Random)

Table 1. Table 514.7C-IXa from MIL-STD-810G w/ Change 1 – Typical Helicopter Vibration parameters

Table 2. Table 514.7C-IXb from MIL-STD-810G w/ Change 1 – Helicopter Vibration Exposure and Variables

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