mechanical problem solving

Problem Solving in Mechanical Engineering With Real World Examples

• Mechanical Engineering

Mechanical engineering is all about solving problems by using science and math. Engineers have to come up with better designs and improve how things are made. They make sure everything works well and lasts long. It’s important because they need to know a lot about their field and think both creatively and logically to find solutions to real problems.

For instance, they might work on making heating and cooling systems use less energy, find ways to cut down on waste when making products, or create new materials for planes and spaceships. These examples show how crucial mechanical engineers are in making technology and industries better.

In simpler terms, mechanical engineers are like problem-solving wizards. They use their deep knowledge and smart thinking to tackle challenges, like making a car engine that uses less fuel or a machine that makes fewer errors. They’re always learning and inventing to make sure the things we use every day are the best they can be.

This is key because their work helps us save money, be safer, and even protect the environment. It’s how they play a big part in pushing technology forward and keeping industries running smoothly.

Understanding Fundamental Principles

In mechanical engineering, it’s crucial to really get thermodynamics, materials science, and how to analyze structures. Knowing these core ideas helps you figure out how forces and materials work together, how energy moves and changes, and how to make sure structures are strong enough to handle different kinds of pressure.

When dealing with complicated systems, you break them down to understand how they work under different situations. For example, when choosing materials, you look closely at their strength, how much they can bend, and how well they conduct heat to make sure they will work well and last a long time. Thermodynamics helps make energy systems work better and use less power. Every solution is carefully made using these ideas to make sure the engineering designs do what they’re supposed to and are safe.

As an example, when building a bridge, engineers will use materials science to pick the right steel that can support the weight of cars over time without bending too much. They’ll apply thermodynamics to design any moving parts, like a drawbridge, to work efficiently with minimal energy waste. By focusing on these principles, engineers make sure the bridge is not only functional, allowing people to cross safely, but also stands the test of time.

Analyzing Complex Systems

To really get how complex machinery works, engineers take it apart to look at each piece. This helps them see how all the parts fit together and make the machine do its job. They start by figuring out where the system begins and ends, then they take a closer look at the smaller parts, like the sensors and motors, and the computer brain that controls everything.

Engineers use special tools and tests, like checking what could go wrong and how likely it is (that’s called FMEA), running computer models, and seeing how changes affect the system. By doing all this, they make sure the machine is safe, reliable, and works well because they’ve checked everything carefully, not left it to luck.

It’s important that they do this because it helps prevent accidents and breakdowns. For example, think about a car: if engineers didn’t test all the parts, like brakes and airbags, we wouldn’t trust them to keep us safe on the road. So, they use these tools to make sure everything is in top shape. This kind of detailed work means that when you use something like a car or a dishwasher, it’s been checked to work properly and safely.

Innovating in Product Design

Creating new and better product designs starts with really understanding how current products work. Mechanical engineers look at these products in detail to figure out how they can make them work better, use less energy, and give people a better experience when using them.

The first step is to carefully study what the product is supposed to do, how people use it, and where it can be improved. Engineers have to take apart complicated parts and processes to spot opportunities for new ideas. They use practical engineering knowledge to make designs that are not just better, but also cost less and are better for the environment. They make sure every part of the new product has a reason to be there and helps make the product both new and useful.

Being committed to making these kinds of advances is a big part of what mechanical engineering is all about in product design.

For example, when engineers worked on a new blender, they saw that the old design was hard to clean. They redesigned the blades to be detachable, which made cleaning easier and the blender more efficient. This change also saved materials, making the blender more eco-friendly.

This kind of thoughtful redesign shows how engineers can make our everyday products better.

Optimizing Manufacturing Processes

In manufacturing, engineers focus on improving the process to achieve faster production, reduced waste, and cost savings. They analyze production methods, examining data and observing operations to identify bottlenecks and inefficiencies. Strategies such as lean manufacturing or Six Sigma are employed to optimize operations and enhance overall efficiency.

Improvements can be made by rearranging machine placement to minimize material movement, implementing proactive maintenance practices to prevent breakdowns, and introducing new technologies like robots. Additionally, engineers work on optimizing the timing of supply deliveries to minimize storage costs. These deliberate actions lead to smarter and more cost-effective manufacturing processes, giving companies a competitive edge.

Ensuring Quality and Reliability

After improving how things are made, it’s crucial to make sure the products are of high quality and can be relied upon. To do this, it’s essential to have a well-thought-out plan for checking the quality and making sure it’s consistent.

Engineers need to create detailed tests that really show what conditions and pressures the products will face in the real world. For example, they might use Failure Mode and Effects Analysis (FMEA) to find and fix possible weaknesses before they cause problems. They also keep an eye on the production process using Statistical Process Control (SPC) to ensure everything stays the same.

Moreover, they use reliability engineering to figure out how to make products last longer. This is all about cutting down on mistakes and making sure the product is as good as it can be, which makes customers happy and maintains the manufacturer’s good name.

To give a specific example, a car manufacturer might use crash tests to simulate real-life accidents. This helps them understand how the car would perform and what they need to improve to ensure passenger safety. By doing this, they not only meet safety standards but also build trust with their customers who know the vehicles are tested thoroughly.

To wrap things up, solving problems in mechanical engineering isn’t simple—it’s a detailed task that involves really understanding the basics, figuring out complicated machinery, being creative when making products, making sure manufacturing is as good as it can be, and always aiming for the highest quality and dependability. It’s vital that all these pieces work together to tackle the tough problems we see in the real world. Mechanical engineers must think things through step by step and apply what they know to keep coming up with new and better ways to move technology forward and make industries run more smoothly.

For example, when engineers work on a new car engine, they need to know exactly how each part works. They must come up with smart designs that make the engine more powerful without using more fuel. They also have to refine the way the engine is built so that the factory can make it without wasting time or materials. Plus, they have to test the engine over and over to make sure it will last a long time and won’t break down. This kind of detailed work is what pushes us ahead, making cars more efficient and reliable for everyone.

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Chapter 1: Fundamental Concepts

1.7 Problem Solving Process

Learning how to use a structured problem solving process will help you to be more organized and support your future courses. Also, it will train your brain how to approach problems. Just like basketball players practice jump shots over and over to train their body how to act in high pressure scenarios, if you are comfortable and familiar with a structured problem solving process, when you’re in a high pressure situation like a test, you can just jump into the problem like muscle memory.

6 Step Problem Solving Method:

• Write out the answer with all necessary information that is given to you. It feels like it takes forever, but it’s important to have the problem and solution next to each other.
• Draw the problem, this is usually a free-body diagram (don’t forget a coordinate frame). Eventually, as you get further into the course, you might need a few drawings. One would be a quick sketch of the problem in the real world, then modelling it into a simplified engineering drawing, and finally the free-body diagram.
• Write out a list of the known/given values with the variable and unit, i.e m = 14 kg   (variable = number unit)
• Write out a list of the unknown values that you will have to solve for in order to solve the problem
• You can also add any assumptions you made here that change the problem.
• Also state any constants, i.e. g = 32.2 ft/m 2   or g = 9.81 m/s 2
• This step helps you to have all of the information in one place when you solve the problem. It’s also important because each number should include units, so you can see if the units match or if you need to convert some numbers so they are all in English or SI. This also gives you the variables side by side to ensure they are unique (so you don’t accidentally have 2 ‘d’ variables and can rename one with a subscript).
• Write a simple sentence or phrase explaining what method/approach you will be using to solve the problem.
• For example: ‘use method of joints’, or equilibrium equations for a rigid body, MMOI for a certain shape, etc.
• This is going to be more important when you get to the later chapters and especially next semester in Dynamics where you can solve the same problem many ways. Might as well practice now!
• This is the actual solving step. This is where you show all the work you have done to solve the problem.
• When you get an answer, restate the variable you are solving for, include the unit, and put a box around the answer.
• Write a simple sentence explaining why (or why not) your answer makes sense. Use logic and common sense for this step.
• When possible, use a second quick numerical analysis to verify your answer. This is the “gut check” to do a quick calculation to ensure your answer is reasonable.
• This is the most confusing step as students often don’t know what to put here and up just writing ‘The number looks reasonable’. This step is vitally important to help you learn how to think about your answer. What does that number mean? What is it close to? For example, if you find that x = 4000 m, that’s a very large distance! In the review, I would say, ‘the object is 4 km long which is reasonable for a long bridge’. See how this is compared to something similar? Or you could do a second calculation to verify the number is correct, such as adding up multiple parts of the problem to confirm the total length is accurate i.e. ‘x + y + z = total, yes it works!’

Additional notes for this course:

• It’s important to include the number and label the steps so it’s clear what you’re doing, as shown in the example below.
• It’s okay if you make mistakes, just put a line through it and keep going.
• Remember your header should include your name, the page number, total number of pages, the course number, and the assignment number. If a problem spans a number of pages, you should include it in the header too.

Key Takeaways

Basically: Use a 6-step structured problem solving process: 1. Problem, 2. Draw, 3. Known & Unknown, 4. Approach, 5. Analysis (Solve), 6. Review

Application: In your future job there is likely a structure for analysis reports that will be used. Each company has a different approach, but most have a standard that should be followed. This is good practice.

Looking ahead: This will be part of every homework assignment.

Written by Gayla & Libby

Engineering Mechanics: Statics Copyright © by Libby (Elizabeth) Osgood; Gayla Cameron; Emma Christensen; Analiya Benny; and Matthew Hutchison is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License , except where otherwise noted.

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