A History of Mechanical Engineering

Ce Zhang Jianming Yang

•

A History of Mechanical
Engineering

123
Ce Zhang Jianming Yang
Tianjin University Memorial University of Newfoundland
Tianjin, China St. John’s, NL, Canada

ISBN 978-981-15-0832-5 ISBN 978-981-15-0833-2 (eBook)

https://doi.org/10.1007/978-981-15-0833-2
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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Historical Stages of Mechanical Development . . . . . . . . . . . . . 2
1.1.1 Ancient Era . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1.2 Modern Era . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Contemporary Era . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Key Relations in History of Mechanical Engineering . . . . . . . . 4
1.2.1 Nature, Society, Science and Technology . . . . . . . . . . . 5
1.2.2 Driving Forces Behind Science and Technology . . . . . . 5
1.2.3 Influence of Society . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4 Mechanical Engineering and Natural Science . . . . . . . . 7
1.2.5 Mechanical Engineering and Related
Technological Fields . . . . . . . . . . . . . . . . . . . . . ..... 8
1.3 Technological Revolution and Industrial Revolution . . . . ..... 9
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 10
2 Ancient Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.1 Three Stages and Three Regions . . . . . . . . . . . . . . . . . 11
2.1.2 The Dawning of Civilization: West Asia and Egypt . . . 12
2.1.3 Brilliance and Straggle of Ancient China . . . . . . . . . . . 13
2.1.4 Twists and Turns in Europe’s Development . . . . . . . . . 17
2.2 Various Ancient Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.1 Simple Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.2 Agricultural Machines . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.3 Blowers and Blast Technology . . . . . . . . . . . . . . . . . . 28
2.2.4 Boats and Ships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2.5 Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2.6 Textile Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.7 Timers and Astronomical Instruments . . . . . . . . . . . . . 37
2.2.8 Lifting Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

v
vi Contents

2.2.9 Weapons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.10 Machines for Rituals and Entertainment . . . . . . . . . . . . 45
2.2.11 Mechanisms and Transmissions . . . . . . . . . . . . . . . . . . 47
2.2.12 Power for Ancient Machines . . . . . . . . . . . . . . . . . . . . 49
2.3 Ancient Manufacturing Technology . . . . . . . . . . . . . . . . . . . . . 50
2.3.1 Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3.2 Forging and Other Press Processing . . . . . . . . . . . . . . . 54
2.3.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.4 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3.5 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Discussion on Ancient Machines . . . . . . . . . . . . . . . . . . . . . . . 60
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3 Social, Scientific and Technological Progresses of Europe
Before Industrial Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1 Social Development Before Industrial Revolution . . . . . . . . . . . 65
3.1.1 Emergence of Capitalist Mode of Production . . . . . . . . 65
3.1.2 Great Discoveries of Geography . . . . . . . . . . . . . . . . . 66
3.1.3 The Renaissance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.4 Religious Reform (the Reformation) . . . . . . . . . . . . . . 67
3.1.5 The Enlightenment . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.6 Bourgeois Revolutions . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Mechanical Science and Technology Before the Industrial
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 69
3.2.1 Leonardo da Vinci . . . . . . . . . . . . . . . . . . . . . . . .... 69
3.2.2 Progresses of Machine Theory Before Industrial
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 70
3.2.3 Mechanical Technology Before the Industrial
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 71
3.3 Establishment and Development of Classical Mechanics . . .... 83
3.3.1 Breakthrough in Astronomy and Liberation of
Scientific Spirit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3.2 Theoretical Background . . . . . . . . . . . . . . . . . . . . . . . 85
3.3.3 Establishment of Classical Mechanics . . . . . . . . . . . . . 87
3.3.4 Limitations of Classical Mechanics . . . . . . . . . . . . . . . 88
3.4 Calculus and Differential Equations . . . . . . . . . . . . . . . . . . . . . 90
3.4.1 Establishment of Calculus . . . . . . . . . . . . . . . . . . . . . . 91
3.4.2 Theory of Differential Equation . . . . . . . . . . . . . . . . . . 91
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4 First Industrial Revolution . ....................... . . . . . . . 95
4.1 A Brief Review . . . . . ....................... . . . . . . . 95
4.1.1 Background of English Industrial Revolution . . . . . . . . 95
4.1.2 Introduction to First Industrial Revolution . . . . . . . . . . 98
Contents vii

4.2 Steam Engine and Transportation Revolution . . . . . . . . . . . . . . 99

4.2.1 Long Process of the Invention . . . . . . . . . . . . . . . . . . . 99
4.2.2 Watt’s Contributions . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2.3 Watt: A Creative Genius . . . . . . . . . . . . . . . . . . . . . . . 102
4.2.4 Epochal Significance . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2.5 Railway Age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2.6 Steam Ships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2.7 Significance of Transportation Revolution . . . . . . . . . . 106
4.3 Mechanical Inventions in First Industrial Revolution . . . . . . . . . 107
4.3.1 Wide Application of Steam Power . . . . . . . . . . . . . . . . 107
4.3.2 Textile and Sewing Machines . . . . . . . . . . . . . . . . . . . 109
4.3.3 Construction and Mining Machines . . . . . . . . . . . . . . . 112
4.3.4 Agricultural Machines . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3.5 Refrigeration Machines . . . . . . . . . . . . . . . . . . . . . . . . 116
4.3.6 Fluid Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.3.7 Weapons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.3.8 Information Machines . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.4 Birth and Early Development of Modern Machine
Building Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.4.1 Status of Machining in 18th Century . . . . . . . . . . . . . . 124
4.4.2 Inventions and Improvements of Machine Tools . . . . . 125
4.4.3 Birth of Interchangeable Parts . . . . . . . . . . . . . . . . . . . 129
4.4.4 The Beginning of Standardization . . . . . . . . . . . . . . . . 131
4.5 Perpetual Motion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5 Second Industrial Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1 Introduction to the Second Industrial Revolution . . . . . . . . . . . . 137
5.1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.1.2 The Age of Electricity . . . . . . . . . . . . . . . . . . . . . . . . 140
5.1.3 Era of Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.1.4 Introduction to Development of Mechanical
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.1.5 Features of the Second Industrial Revolution . . . . . . . . 145
5.2 Internal Combustion Engine and New Transportation
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.2.1 Invention and Development of Internal
Combustion Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.2.2 Invention and Early Development of Automobile . . . . . 150
5.2.3 Invention and Early Development of Aircraft . . . . . . . . 153
5.2.4 Other Changes in Transportation . . . . . . . . . . . . . . . . . 157
viii Contents

5.3 Machine Inventions in Second Industrial Revolution . . . . . . . . . 160

5.3.1 Power Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.3.2 Mining Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.3.3 Construction Machinery . . . . . . . . . . . . . . . . . . . . . . . 169
5.3.4 Pumps and Compressors . . . . . . . . . . . . . . . . . . . . . . . 170
5.3.5 Information Machinery . . . . . . . . . . . . . . . . . . . . . . . . 171
5.3.6 Weapons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.3.7 Other Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.4 Machine Manufacturing in 2nd Industrial Revolution . . . . . . . . 176
5.4.1 Development of Machine Tools . . . . . . . . . . . . . . . . . 177
5.4.2 Tool Materials and Cutting Speed . . . . . . . . . . . . . . . . 182
5.4.3 Progress in Metrology . . . . . . . . . . . . . . . . . . . . . . . . 183
5.4.4 Taylor’s Scientific Management . . . . . . . . . . . . . . . . . 184
5.4.5 Ford’s Mass Production . . . . . . . . . . . . . . . . . . . . . . . 185
5.4.6 Standardization and Serialization . . . . . . . . . . . . . . . . . 187
5.5 Trends of Development of Machinery . . . . . . . . . . . . . . . . . . . 188
5.5.1 High Speed and Large Capacity . . . . . . . . . . . . . . . . . 189
5.5.2 Precision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.5.3 Light Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.5.4 Semi-automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6 Progress of Mathematics and Mechanics During Industrial
Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1 Progress of Mathematics Related to Mechanical
Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.1 Calculus of Variations . . . . . . . . . . . . . . . . . . . . . . . . 197
6.1.2 Differential Geometry . . . . . . . . . . . . . . . . . . . . . . . . . 198
6.1.3 Linear Algebra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
6.1.4 Probability Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6.1.5 Graph Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.2 Further Progress of Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . 203
6.2.1 Analytical Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . 204
6.2.2 Elastic Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
6.2.3 Plastic Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
6.2.4 Mechanics of Materials . . . . . . . . . . . . . . . . . . . . . . . . 209
6.2.5 Theory of Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6.2.6 Fluid Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
6.2.7 Relationship Between Mathematics
and Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Contents ix

7 Birth and Development of Modern Mechanical Engineering

Discipline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.1 Birth of Mechanical Engineering Discipline . . . . . . . . . . . . . . . 219
7.1.1 Birth of Mechanism Theory . . . . . . . . . . . . . . . . . . . . 220
7.1.2 Theoretical Kinematics in France . . . . . . . . . . . . . . . . 222
7.1.3 Foundation of Institution of Mechanical Engineers . . . . 223
7.2 Development of Modern Mechanism Subject . . . . . . . . . . . . . . 224
7.2.1 German School and Russian School in Mechanism . . . 224
7.2.2 Applications and Theory of Linkages . . . . . . . . . . . . . 229
7.2.3 Evolution and Design of Cam Mechanism . . . . . . . . . . 232
7.3 Mechanical Vibration Theory and Application . . . . . . . . . . . . . 236
7.4 Machine Dynamics in Modern Times . . . . . . . . . . . . . . . . . . . . 239
7.4.1 Dynamic Analysis Methods . . . . . . . . . . . . . . . . . . . . 239
7.4.2 Rotor Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
7.4.3 Balancing of Mechanism . . . . . . . . . . . . . . . . . . . . . . 245
7.5 Evolution of Mechanical and Hydraulic Transmissions . . . . . . . 247
7.5.1 Mechanical Transmissions . . . . . . . . . . . . . . . . . . . . . 247
7.5.2 Hydraulic Transmission . . . . . . . . . . . . . . . . . . . . . . . 250
7.6 Modern Machine Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
7.6.1 Development Stages of Machine Design . . . . . . . . . . . 254
7.6.2 Descriptive Geometry . . . . . . . . . . . . . . . . . . . . . . . . . 255
7.6.3 Independence of Machine Design . . . . . . . . . . . . . . . . 256
7.6.4 Strength of Mechanical Structures . . . . . . . . . . . . . . . . 257
7.6.5 Formation of Design Method for Machine
Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.7 Modern Machine Manufacturing . . . . . . . . . . . . . . . . . . . . . . . 263
7.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
7.7.2 Theory of Metal Cutting . . . . . . . . . . . . . . . . . . . . . . . 264
7.7.3 Theory of Machining Precision . . . . . . . . . . . . . . . . . . 266
7.8 Evolution of Discipline in Modern Time . . . . . . . . . . . . . . . . . 269
7.8.1 Subject Parturition . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
7.8.2 Subject Advancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8 Modern Higher Education in Mechanical Engineering . . . . . . . . . . 275
8.1 Modern Engineering Education in 19th Century . . . . . . . . . . . . 276
8.1.1 Britain: Declining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.1.2 France: Pioneer of Modern Engineering Education . . . . 278
8.1.3 Germany: Creation of Modern University
and Leader in Mechanical Engineering . . . . . . . . . . . . 280
8.1.4 U.S.: Rising in Engineering Education . . . . . . . . . . . . . 284
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8.2 Mechanical Engineering Education in First Half of 20th

Century . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
8.2.1 Soviet Union: Extremely Narrow Specialized
Education . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
8.2.2 Jewish Refugee Wave . . . . . . . . . . . . . . . . . . . . . . . . . 290
8.2.3 U.S.: New World Center of Science, Technology
and Engineering Education . . . . . . . . . . . . . . . . . . . . . 291
8.3 Two Models of Engineering Education . . . . . . . . . . . . . . . . . . 292
8.3.1 General Education and Specialized Education . . . . . . . 292
8.3.2 Case Study and Comparison . . . . . . . . . . . . . . . . . . . . 293
8.3.3 Comparison of the Two Models . . . . . . . . . . . . . . . . . 295
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
9 Third Technological Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1 Scientific Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1.1 New Revolution in Physics . . . . . . . . . . . . . . . . . . . . . 299
9.1.2 Birth of Systems Science . . . . . . . . . . . . . . . . . . . . . . 301
9.1.3 Nonlinear Science . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
9.2 Social Background of Third Technological Revolution . . . . . . . 309
9.2.1 WWII: Midwife of New Technological Revolution . . . 309
9.2.2 Post-war World . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
9.3 Main Contents of Third Technological Revolution . . . . . . . . . . 315
9.3.1 Information Technology . . . . . . . . . . . . . . . . . . . . . . . 315
9.3.2 Aerospace Technology . . . . . . . . . . . . . . . . . . . . . . . . 322
9.3.3 New Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
9.3.4 New Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
9.3.5 Modern Bio-technology . . . . . . . . . . . . . . . . . . . . . . . 331
9.3.6 Marine Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 332
9.4 Characteristics of Third Technological Revolution . . . . . . . . . . 333
9.4.1 Characters of Third Technological Revolution . . . . . . . 333
9.4.2 New Industrial Revolution . . . . . . . . . . . . . . . . . . . . . 336
9.5 Progress in Mathematics and Mechanics . . . . . . . . . . . . . . . . . . 338
9.5.1 Numerical Algorithms . . . . . . . . . . . . . . . . . . . . . . . . 338
9.5.2 Progress in Vibration Theory . . . . . . . . . . . . . . . . . . . 341
9.5.3 Multibody Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . 344
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
10 Summary of Mechanical Engineering in New Era . . . . . . . . . . . . . 351
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
10.1.1 Four Driving Forces Behind Mechanical
Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
10.1.2 Booming of Mechanical Engineering . . . . . . . . . . . . . . 354
Contents xi

10.2 Trends of Mechanical Products in New Era . . . . . . . . . . . . . . . 355

10.2.1 Higher Speed and More Powerful . . . . . . . . . . . . . . . . 356
10.2.2 Higher Level of Accuracy . . . . . . . . . . . . . . . . . . . . . . 357
10.2.3 Higher Level of Reliability . . . . . . . . . . . . . . . . . . . . . 357
10.2.4 Urgent Need for Lighter Weight . . . . . . . . . . . . . . . . . 358
10.2.5 Higher Performance to Cost Ratio . . . . . . . . . . . . . . . . 359
10.2.6 Higher Level of Environmental-Friendliness . . . . . . . . . 359
10.2.7 Higher Level of Safety and Comfortability . . . . . . . . . 360
10.2.8 Diversification and Personalization . . . . . . . . . . . . . . . 360
10.3 Important Inventions and Innovations in New Era . . . . . . . . . . . 361
10.3.1 Mechatronic Products . . . . . . . . . . . . . . . . . . . . . . . . . 362
10.3.2 Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
10.3.3 High Speed Rail Systems . . . . . . . . . . . . . . . . . . . . . . 369
10.3.4 Large Scale Construction Machinery . . . . . . . . . . . . . . 372
10.3.5 Information Machines . . . . . . . . . . . . . . . . . . . . . . . . . 373
10.3.6 Power Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
10.3.7 Textile Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
10.3.8 Agricultural Machines . . . . . . . . . . . . . . . . . . . . . . . . 375
10.4 Important Developments in Manufacturing . . . . . . . . . . . . . . . . 376
10.4.1 Automotive Manufacturing . . . . . . . . . . . . . . . . . . . . . 377
10.4.2 Aerospace Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
10.4.3 Large Power Generating Systems . . . . . . . . . . . . . . . . 380
10.4.4 IC Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
10.4.5 Machine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
10.5 Complex Electromechanical System . . . . . . . . . . . . . . . . . . . . . 383
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
11 Mechanical Design in New Era . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
11.1.1 Development of Machine Design . . . . . . . . . . . . . . . . 390
11.1.2 Design Theory and Methodology . . . . . . . . . . . . . . . . 392
11.2 Concurrent Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
11.3 Creative Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
11.3.1 Birth of Creatology in U.S. . . . . . . . . . . . . . . . . . . . . . 394
11.3.2 TRIZ in USSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
11.3.3 Creative Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
11.3.4 Reverse Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 398
11.3.5 Bionic Design (Biomimicry) . . . . . . . . . . . . . . . . . . . . 398
11.4 Computer Graphics and Computer-Aided Design . . . . . . . . . . . 400
11.4.1 Computer Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
11.4.2 Computer-Aided Design . . . . . . . . . . . . . . . . . . . . . . . 403
xii Contents

11.5 Advanced Design Methods for Improving Quality . . . . . . . . . . 405

11.5.1 Optimum Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
11.5.2 Design for Reliability . . . . . . . . . . . . . . . . . . . . . . . . . 406
11.5.3 Design for Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
11.6 Dynamic Design and Vibration Control . . . . . . . . . . . . . . . . . . 408
11.6.1 Dynamic Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
11.6.2 Vibration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
11.7 Other Advanced Design Methods . . . . . . . . . . . . . . . . . . . . . . . 416
11.7.1 Value Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
11.7.2 Industrial Design and Ergonomics . . . . . . . . . . . . . . . . 417
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
12 Manufacturing Technology During New Era . . . . . . . . . . . . . . . . . 423
12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
12.1.1 Challenges in New Era . . . . . . . . . . . . . . . . . . . . . . . . 423
12.1.2 Developments of Manufacturing Technologies
in New Era . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
12.2 Automation: Backbone of Advanced Manufacturing . . . . . . . . . 428
12.2.1 NC Machining and NC Machine Tools . . . . . . . . . . . . 429
12.2.2 Process Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
12.2.3 Integration of CAD/CAPP/CAM . . . . . . . . . . . . . . . . . 432
12.2.4 Flexible Manufacturing Systems . . . . . . . . . . . . . . . . . 432
12.2.5 Robots in Manufacturing . . . . . . . . . . . . . . . . . . . . . . 434
12.3 Progress of Machining Technology . . . . . . . . . . . . . . . . . . . . . 435
12.3.1 Tool Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
12.3.2 High-Speed Machining (HSM) . . . . . . . . . . . . . . . . . . 436
12.3.3 Precision and Ultra-Precision Machining . . . . . . . . . . . 437
12.3.4 Machining of Difficult-to-Cut Materials . . . . . . . . . . . . 438
12.3.5 Near-Dry and Dry Machining . . . . . . . . . . . . . . . . . . . 439
12.3.6 Vibration Control of Machining . . . . . . . . . . . . . . . . . 439
12.3.7 Advance in Machine Tools . . . . . . . . . . . . . . . . . . . . . 442
12.4 Machining of Free-Form Surfaces . . . . . . . . . . . . . . . . . . . . . . 443
12.4.1 Free-Form Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
12.4.2 Machining of Spiral Bevel Gears . . . . . . . . . . . . . . . . . 444
12.5 Non-traditional Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
12.5.1 Thermal Energy Processes . . . . . . . . . . . . . . . . . . . . . 447
12.5.2 Mechanical Energy Processes . . . . . . . . . . . . . . . . . . . 449
12.5.3 Electrochemical Machining . . . . . . . . . . . . . . . . . . . . . 450
12.6 Additive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
12.6.1 Rapid Prototyping (RP) . . . . . . . . . . . . . . . . . . . . . . . 451
12.6.2 3D Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Contents xiii

12.7 Green Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

12.7.1 Green Manufacturing: From Awareness to Action . . . . 454
12.7.2 Scope of Green Manufacturing . . . . . . . . . . . . . . . . . . 455
12.7.3 Remanufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
12.8 Some Other Progresses in Manufacturing . . . . . . . . . . . . . . . . . 458
12.8.1 Computer Integrated Manufacturing System . . . . . . . . . 458
12.8.2 Distributed Manufacturing . . . . . . . . . . . . . . . . . . . . . 460
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
13 Development of Theories in Mechanical Engineering
of New Era . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
13.1 Mechanism and Machine Science . . . . . . . . . . . . . . . . . . . . . . 465
13.1.1 American School . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
13.1.2 Progress in Kinematics . . . . . . . . . . . . . . . . . . . . . . . . 467
13.1.3 New Types of Mechanism . . . . . . . . . . . . . . . . . . . . . 469
13.1.4 Mechanism Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . 470
13.1.5 MMS in China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
13.2 Mechanical Power Transmissions . . . . . . . . . . . . . . . . . . . . . . . 474
13.2.1 Standards for Strength Evaluation of Gears . . . . . . . . . 474
13.2.2 Gear Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
13.2.3 Progress in Theory of Gearing . . . . . . . . . . . . . . . . . . 475
13.2.4 New Types of Meshing Transmission . . . . . . . . . . . . . 476
13.2.5 Other Mechanical Power Transmissions . . . . . . . . . . . . 478
13.2.6 Informatizition and Intelligentization . . . . . . . . . . . . . . 480
13.3 Robotics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
13.3.1 Robot Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
13.3.2 Robot Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
13.4 Machine Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
13.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
13.4.2 Analytical Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . 487
13.4.3 Refining Dynamic Modeling . . . . . . . . . . . . . . . . . . . . 487
13.4.4 Progress in Dynamic Analysis and Simulation . . . . . . . 490
13.4.5 Branches of Machine Dynamics . . . . . . . . . . . . . . . . . 490
13.5 Theories of Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
13.5.1 Fatigue Design Methods . . . . . . . . . . . . . . . . . . . . . . . 493
13.5.2 Development of Fracture Mechanics . . . . . . . . . . . . . . 494
13.5.3 Intelligent Structure and Health Monitoring . . . . . . . . . 496
13.6 Tribology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
13.6.1 Modern Progress in Research on Friction,
Wear and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 497
13.6.2 Contemporary Advance in Tribology Research . . . . . . . 498
xiv Contents

13.7 Micro-electro-Mechanical System . . . . . . . . . . . . . . . . . . . . . . 499

13.7.1 Birth and Development of MEMS . . . . . . . . . . . . . . . . 500
13.7.2 Application Prospect of MEMS . . . . . . . . . . . . . . . . . . 501
13.7.3 Theoretical Researches on MEMS . . . . . . . . . . . . . . . . 502
13.8 Fluid Transmission and Control . . . . . . . . . . . . . . . . . . . . . . . . 503
13.9 Contemporary Evolution of Discipline of Mechanical
Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
13.9.1 Subject Advancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
13.9.2 Subject Intercrossing . . . . . . . . . . . . . . . . . . . . . . . . . 505
13.9.3 Subject Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
14 Development of Other Manufacturing Processes . . . . . . . . . . . . . . . 511
14.1 Development of Casting Technology . . . . . . . . . . . . . . . . . . . . 511
14.1.1 Casting Technology During Industrial Revolutions . . . . 512
14.1.2 Casting Technology in New Technological
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
14.2 Development of Metal Forming . . . . . . . . . . . . . . . . . . . . . . . . 515
14.2.1 Forging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
14.2.2 Rolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
14.2.3 Pressworking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
14.2.4 Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
14.2.5 Cold Forging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
14.2.6 Spinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
14.3 Development of Welding Technology . . . . . . . . . . . . . . . . . . . 522
14.3.1 Welding Technologies in 19th Century . . . . . . . . . . . . 522
14.3.2 Welding Technologies in First Half of 20th
Century . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
14.3.3 Welding Technologies in Third Technological
Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
14.4 Development of Other Blank Forming Method . . . . . . . . . . . . . 526
14.4.1 Explosive Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . 526
14.4.2 Powder Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
14.4.3 Shaping of Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
14.5 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

Appendix: People in This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545