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Practical Machinery Management for Process Plants: Machinery Failure Analysis and Troubleshooting (Volume 2, Third Edition)
Mechanical Engineering is an engineering discipline that involves the application of principles of physics for analysis, design, manufacturing, and maintenance of mechanical systems. Mechanical engineering is one of the oldest and broadest engineering disciplines.
Mechanical engineers design and build engines and power plants,structures and vehicles of all sizes...It requires a solid understanding of core concepts including mechanics, kinematics, thermodynamics, fluid mechanics, and energy. Mechanical engineers use the core principles as well as other knowledge in the field to design and analyze motor vehicles, aircraft, heating and cooling systems, watercraft, manufacturing plants, industrial equipment and machinery, robotics, medical devices and more.
Mechanical engineers design and build engines and power plants,structures and vehicles of all sizes...It requires a solid understanding of core concepts including mechanics, kinematics, thermodynamics, fluid mechanics, and energy. Mechanical engineers use the core principles as well as other knowledge in the field to design and analyze motor vehicles, aircraft, heating and cooling systems, watercraft, manufacturing plants, industrial equipment and machinery, robotics, medical devices and more.
Standards set by each country's accreditation society are intended to provide for uniformity in fundamental subject material, promote competence among graduating engineers, and to maintain confidence in the engineering profession as a whole. Engineering programs in the U.S., for instance, are required by ABET to show that their students can "work professionally in both thermal and mechanical systems areas."The specific courses required to graduate, however, may differ from program to program. Universities will often combine multiple subjects into a single class or split a subject into multiple classes, depending on the faculty available and the university's major area(s) of research. Fundamental subjects of mechanical engineering usually include:
statics and dynamics strength of materials and solid mechanics instrumentation and measurement thermodynamics, heat transfer, energy conversion, and HVAC fluid mechanics and fluid dynamics mechanism design (including kinematics and dynamics) manufacturing technology or processes hydraulics and pneumatics engineering design mechatronics and control theory drafting, CAD (usually including solid modeling), and CAM
Mechanical engineers are also expected to understand and be able to apply basic concepts from chemistry, chemical engineering, electrical engineering, civil engineering, and physics. Most mechanical engineering programs include several semesters of calculus, as well as advanced mathematical concepts which may include differential equations and partial differential equations, linear and modern algebra, and differential geometry, among others.
In addition to the core mechanical engineering curriculum, many mechanical engineering programs offer more specialized programs and classes, such as robotics, transport and logistics, cryogenics, fuel technology, automotive engineering, biomechanics, vibration, optics and others, if a separate department does not exist for these subjects.
Most mechanical engineering programs also require varying amounts of research or community projects to gain practical problem-solving experience. Mechanical engineering students usually hold one or more internships while studying, though this is not typically mandated by the university.
statics and dynamics strength of materials and solid mechanics instrumentation and measurement thermodynamics, heat transfer, energy conversion, and HVAC fluid mechanics and fluid dynamics mechanism design (including kinematics and dynamics) manufacturing technology or processes hydraulics and pneumatics engineering design mechatronics and control theory drafting, CAD (usually including solid modeling), and CAM
Mechanical engineers are also expected to understand and be able to apply basic concepts from chemistry, chemical engineering, electrical engineering, civil engineering, and physics. Most mechanical engineering programs include several semesters of calculus, as well as advanced mathematical concepts which may include differential equations and partial differential equations, linear and modern algebra, and differential geometry, among others.
In addition to the core mechanical engineering curriculum, many mechanical engineering programs offer more specialized programs and classes, such as robotics, transport and logistics, cryogenics, fuel technology, automotive engineering, biomechanics, vibration, optics and others, if a separate department does not exist for these subjects.
Most mechanical engineering programs also require varying amounts of research or community projects to gain practical problem-solving experience. Mechanical engineering students usually hold one or more internships while studying, though this is not typically mandated by the university.
Many mechanical engineering companies, especially those in industrialized nations, have begun to incorporate computer-aided engineering (CAE) programs into their existing design and analysis processes, including 2D and 3D solid modeling computer-aided design (CAD). This method has many benefits, including easier and more exhaustive visualization of products, the ability to create virtual assemblies of parts, and the ease of use in designing mating interfaces and tolerances.
Other CAE programs commonly used by mechanical engineers include product lifecycle management (PLM) tools and analysis tools used to perform complex simulations. Analysis tools may be used to predict product response to expected loads, including fatigue life and manufacturability. These tools include finite element analysis (FEA), computational fluid dynamics (CFD), and computer-aided manufacturing (CAM).
Using CAE programs, a mechanical design team can quickly and cheaply iterate the design process to develop a product that better meets cost, performance, and other constraints. No physical prototype need be created until the design nears completion, allowing hundreds or thousands of designs to be evaluated, instead of a relative few. In addition, CAE analysis programs can model complicated physical phenomena which cannot be solved by hand, such as viscoelasticity, complex contact between mating parts, or non-Newtonian flows
Using CAE programs, a mechanical design team can quickly and cheaply iterate the design process to develop a product that better meets cost, performance, and other constraints. No physical prototype need be created until the design nears completion, allowing hundreds or thousands of designs to be evaluated, instead of a relative few. In addition, CAE analysis programs can model complicated physical phenomena which cannot be solved by hand, such as viscoelasticity, complex contact between mating parts, or non-Newtonian flows
Other CAE programs commonly used by mechanical engineers include product lifecycle management (PLM) tools and analysis tools used to perform complex simulations. Analysis tools may be used to predict product response to expected loads, including fatigue life and manufacturability. These tools include finite element analysis (FEA), computational fluid dynamics (CFD), and computer-aided manufacturing (CAM).
Using CAE programs, a mechanical design team can quickly and cheaply iterate the design process to develop a product that better meets cost, performance, and other constraints. No physical prototype need be created until the design nears completion, allowing hundreds or thousands of designs to be evaluated, instead of a relative few. In addition, CAE analysis programs can model complicated physical phenomena which cannot be solved by hand, such as viscoelasticity, complex contact between mating parts, or non-Newtonian flows
Using CAE programs, a mechanical design team can quickly and cheaply iterate the design process to develop a product that better meets cost, performance, and other constraints. No physical prototype need be created until the design nears completion, allowing hundreds or thousands of designs to be evaluated, instead of a relative few. In addition, CAE analysis programs can model complicated physical phenomena which cannot be solved by hand, such as viscoelasticity, complex contact between mating parts, or non-Newtonian flows
The field of mechanical engineering can be thought of as a collection of many mechanical disciplines. Several of these subdisciplines which are typically taught at the undergraduate level are listed below, with a brief explanation and the most common application of each. Some of these subdisciplines are unique to mechanical engineering, while others are a combination of mechanical engineering and one or more other disciplines. Most work that a mechanical engineer does uses skills and techniques from several of these subdisciplines, as well as specialized subdisciplines. Specialized subdisciplines, as used in this article, are more likely to be the subject of graduate studies or on-the-job training than undergraduate research.
Mechanics:
Mechanics is, in the most general sense, the study of forces and their effect upon matter. Typically, engineering mechanics is used to analyze and predict the acceleration and deformation (both elastic and plastic) of objects under known forces (also called loads) or stresses. Subdisciplines of mechanics includeStatics, the study of non-moving bodies under known loads Dynamics (or kinetics), the study of how forces affect moving bodies Mechanics of materials, the study of how different materials deform under various types of stress Fluid mechanics, the study of how fluids react to forces Continuum mechanics, a method of applying mechanics that assumes that objects are continuous (rather than discrete) Mechanical engineers typically use mechanics in the design or analysis phases of engineering. If the engineering project were the design of a vehicle, statics might be employed to design the frame of the vehicle, in order to evaluate where the stresses will be most intense. Dynamics might be used when designing the car's engine, to evaluate the forces in the pistons and cams as the engine cycles. Mechanics of materials might be used to choose appropriate materials for the frame and engine. Fluid mechanics might be used to design a ventilation system for the vehicle (see HVAC), or to design the intake system for the engine.
Kinematics:
Kinematics is the study of the motion of bodies (objects) and systems (groups of objects), while ignoring the forces that cause the motion. The movement of a crane and the oscillations of a piston in an engine are both simple kinematic systems. The crane is a type of open kinematic chain, while the piston is part of a closed four bar linkage.Mechanical engineers typically use kinematics in the design and analysis of mechanisms. Kinematics can be used to find the possible range of motion for a given mechanism, or, working in reverse, can be used to design a mechanism that has a desired range of motion.
Mechatronics and robotics:
Mechatronics is an interdisciplinary branch of mechanical engineering, electrical engineering and software engineering that is concerned with integrating electrical and mechanical engineering to create hybrid systems. In this way, machines can be automated through the use of electric motors, servo-mechanisms, and other electrical systems in conjunction with special software. A common example of a mechatronics system is a CD-ROM drive. Mechanical systems open and close the drive, spin the CD and move the laser, while an optical system reads the data on the CD and converts it to bits. Integrated software controls the process and communicates the contents of the CD to the computer.
Robotics is the application of mechatronics to create robots, which are often used in industry to perform tasks that are dangerous, unpleasant, or repetitive. These robots may be of any shape and size, but all are preprogrammed and interact physically with the world. To create a robot, an engineer typically employs kinematics (to determine the robot's range of motion) and mechanics (to determine the stresses within the robot).
Robots are used extensively in industrial engineering. They allow businesses to save money on labor, perform tasks that are either too dangerous or too precise for humans to perform them economically, and to insure better quality. Many companies employ assembly lines of robots, and some factories are so robotized that they can run by themselves. Outside the factory, robots have been employed in bomb disposal, space exploration, and many other fields. Robots are also sold for various residential applications.
Structural analysis:
Structural analysis is the branch of mechanical engineering (and also civil engineering) devoted to examining why and how objects fail. Structural failures occur in two general modes: static failure, and fatigue failure. Static structural failure occurs when, upon being loaded (having a force applied) the object being analyzed either breaks or is deformed plastically, depending on the criterion for failure. Fatigue failure occurs when an object fails after a number of repeated loading and unloading cycles. Fatigue failure occurs because of imperfections in the object: a microscopic crack on the surface of the object, for instance, will grow slightly with each cycle (propagation) until the crack is large enough to cause ultimate failure.
Failure is not simply defined as when a part breaks, however; it is defined as when a part does not operate as intended. Some systems, such as the perforated top sections of some plastic bags, are designed to break. If these systems do not break, failure analysis might be employed to determine the cause.
Structural analysis is often used by mechanical engineers after a failure has occurred, or when designing to prevent failure. Engineers often use online documents and books such as those published by ASM to aid them in determining the type of failure and possible causes.
Structural analysis may be used in the office when designing parts, in the field to analyze failed parts, or in laboratories where parts might undergo controlled failure tests.
Thermodynamics and thermo-science:
Thermodynamics is an applied science used in several branches of engineering, including mechanical and chemical engineering. At its simplest, thermodynamics is the study of energy, its use and transformation through a system. Typically, engineering thermodynamics is concerned with changing energy from one form to another. As an example, automotive engines convert chemical energy (enthalpy) from the fuel into heat, and then into mechanical work that eventually turns the wheels.
Thermodynamics principles are used by mechanical engineers in the fields of heat transfer, thermofluids, and energy conversion. Mechanical engineers use thermo-science to design engines and power plants, heating, ventilation, and air-conditioning (HVAC) systems, heat exchangers, heat sinks, radiators, refrigeration, insulation, and others.
Drafting:
Drafting or technical drawing is the means by which mechanical engineers create instructions for manufacturing parts. A technical drawing can be a computer model or hand-drawn schematic showing all the dimensions necessary to manufacture a part, as well as assembly notes, a list of required materials, and other pertinent information. A U.S. mechanical engineer or skilled worker who creates technical drawings may be referred to as a drafter or draftsman. Drafting has historically been a two-dimensional process, but computer-aided design (CAD) programs now allow the designer to create in three dimensions.
Instructions for manufacturing a part must be fed to the necessary machinery, either manually, through programmed instructions, or through the use of a computer-aided manufacturing (CAM) or combined CAD/CAM program. Optionally, an engineer may also manually manufacture a part using the technical drawings, but this is becoming an increasing rarity, with the advent of computer numerically controlled (CNC) manufacturing. Engineers primarily manually manufacture parts in the areas of applied spray coatings, finishes, and other processes that cannot economically or practically be done by a machine.
Drafting is used in nearly every subdiscipline of mechanical engineering, and by many other branches of engineering and architecture. Three-dimensional models created using CAD software are also commonly used in finite element analysis (FEA) and computational fluid dynamics (CFD).
Mechanical engineers are constantly pushing the boundaries of what is physically possible in order to produce safer, cheaper, and more efficient machines and mechanical systems. Some technologies at the cutting edge of mechanical engineering are listed below.
Composites:
Composites or composite materials are a combination of materials which provide different physical characteristics than either material separately. Composite material research within mechanical engineering typically focuses on designing (and, subsequently, finding applications for) stronger or more rigid materials while attempting to reduce weight, susceptibility to corrosion, and other undesirable factors. Carbon fiber reinforced composites, for instance, have been used in such diverse applications as spacecraft and fishing rods.
Mechatronics:
Mechatronics is the synergistic combination of mechanical engineering, electronic engineering, and software engineering. The purpose of this interdisciplinary engineering field is the study of automata from an engineering perspective and serves the purposes of controlling advanced hybrid systems.
Nanotechnology:
At the smallest scales, mechanical engineering becomes nanotechnology and molecular engineering—one speculative goal of which is to create a molecular assembler to build molecules and materials via mechanosynthesis. For now this goal remains within exploratory engineering.
Finite Element Analysis:
This field is not new, as the basis of Finite Element Analysis (FEA) or Finite Element Method (FEM) dates back to 1941. But evolution of computers has made FEM a viable option for analysis of structural problems. Many commercial codes such as ANSYS, Nastran and ABAQUS are widely used in industry for research and design of components.
Other techniques such as Finite Difference Method (FDM) and Finite Volume Method (FVM) are employed to solve problems relating heat and mass transfer, fluid flows, fluid surface interaction etc.
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