Flap is an important accretion device in the take-off and landing of civil transport aircraft. The reliability of flap system plays a vital role in flight safety, and airworthiness regulations explicitly require safe return capacities after flap failure. A significant amount of simulation and analysis work of flap mechanism fault has been carried out at home and abroad, but there is relatively little research data on physical test technologies. The simulation technology of flap mechanism fracture fault is studied and the flap actuator disengagement dummy is designed to realize the function switching between normal and fault state of flap actuator. The energy absorbing element and flap interconnect structure dummy were designed to meet the test requirements, and the energy calibration curve of the energy absorbing element was obtained through the drop hammer test. The flap mechanism fault simulation and strength test were carried out on the full-size structure, and the possible single actuator fracture fault of the flap during flight was simulated. Accurate flap attitude and mechanism force transfer path change, flap interconnect structure free travel, and impact energy were obtained after the fault, which provided foundation for optimizing the design parameters of the flap interconnect structure dummy.