One notable project centred around a fabricated structure designed to stop a train by engaging directly with the rails. This structure was secured in place using clamped feet, which were engineered to slide along the rail upon impact with the train. The effectiveness of this braking mechanism depended on a complex interplay of factors, including the coefficient of friction between the contact surfaces of the feet and the rail, the torque applied to the clamps, and the mass and velocity of the train. Precise control over these variables was essential to achieving the desired stopping distance while maintaining safety and structural integrity. This work required not only a solid grasp of mechanical principles but also a practical understanding of material behaviour under dynamic loading conditions, making it a compelling example of applied engineering in a high-stakes environment.
During my mechanical design career, I made extensive use of Finite Element Analysis (FEA) to evaluate and ensure the structural integrity of complex mechanical components and assemblies. This process was integral to my workflow, allowing me to simulate real-world conditions and identify potential failure points before physical prototyping. I routinely defined appropriate mesh sizes to balance computational efficiency with result accuracy, ensuring that stress concentrations and deformation patterns were captured with precision. A key aspect of my FEA work involved accurately modelling surface interactions within CAD environments, such as contact conditions, frictional behaviour, and boundary constraints, which are critical for realistic simulations. Interpreting FEA results enabled me to make informed design decisions, often leading to simplified geometries and optimized material usage. These improvements not only enhanced product performance but also contributed to significant cost reductions during manufacturing. Leveraging FEA as a design tool deepened my understanding of mechanical systems and empowered me to develop solutions that were both innovative and practical.
