Mechanical Engineering Handbook

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Mechanical Engineering Handbook

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Preface excerpt

Mechanical engineering is a broad and complex field within the world of engineering and has close relations to many other fields. It is an important economic factor for all industrialized countries and the global market allows for wide international competition for products and processes in this field. To stay up to date with scientific findings and to apply existing knowledge in mechanical engineering it is important to renew and continuously update existing information.

The editors of this Springer Handbook on Mechanical Engineering have worked successfully with 92 authors worldwide to include chapters about all relevant mechanical engineering topics. However, this Handbook cannot claim to cover every aspect or detail of the mechanical engineering areas or fields included, and where mechanical engineers are currently present and contributing their expertise and knowledge towards the challenges of a better world. However, this Handbook will be a valuable guide for all who design, develop, manufacture, operate, and use mechanical artefacts. We also hope to spark interest in the field of mechanical engineering from others. In this Handbook, high-school students can get a first glance at the options in this field and possible career moves.

We, the editors, would like to express our gratitude and thanks to all of the authors of this Handbook, who have devoted a considerable amount of time towards this project. We would like to thank them for their patience and cooperation, and we hope for a long-lasting partnership in this ambitious project. We would also most sincerely like to thank our managers and friends at Springer and le-tex. The executives at Springer–Verlag were always most cooperative and supportive of this Handbook. Without Dr. Skolaut’s continuous help and encouragement and Ms. Moebes’ and Mr. Wieczorek’s almost daily requests for corrections, improvements, and progress reports it would have taken another few years – if ever – to publish this Handbook. Stürtz has done a fantastic job in printing and binding. Finally we would like to thank all the people we work with in our departments and universities, who tolerated the time and effort spent on this book.

Finally, we know that there is always room for improvement – with this Handbook as with most engineering products and approaches. We, as well as the authors welcome your fair hints, comments, and criticism. Through this Handbook and with the authors’ efforts, we would also like to draw your attention to what has been accomplished for the benefit of the engineering world and society.

TOC

List of Abbreviations ................................................................................. XXIII
Part A Fundamentals of Mechanical Engineering
1 Introduction to Mathematics for Mechanical Engineering
Ramin S. Esfandiari ................................................................................. 3
1.1 Complex Analysis........................................................................... 4
1.2 Differential Equations.................................................................... 9
1.3 Laplace Transformation ................................................................. 15
1.4 Fourier Analysis ............................................................................. 24
1.5 Linear Algebra............................................................................... 26
References .............................................................................................. 33
2 Mechanics
Hen-Geul Yeh, Hsien-Yang Yeh, Shouwen Yu ............................................ 35
2.1 Statics of Rigid Bodies ................................................................... 36
2.2 Dynamics ...................................................................................... 52
References .............................................................................................. 71
Part B Applications in Mechanical Engineering
3 Materials Science and Engineering
Jens Freudenberger, Joachim Göllner, Martin Heilmaier, Gerhard Mook,
Holger Saage, Vivek Srivastava, Ulrich Wendt............................................ 75
3.1 Atomic Structure and Microstructure............................................... 77
3.2 Microstructure Characterization...................................................... 98
3.3 Mechanical Properties ................................................................... 108
3.4 Physical Properties ........................................................................ 122
3.5 Nondestructive Inspection (NDI) ..................................................... 126
3.6 Corrosion ...................................................................................... 141
3.7 Materials in Mechanical Engineering .............................................. 157
References .............................................................................................. 218
4 Thermodynamics
Frank Dammel, Jay M. Ochterbeck, Peter Stephan...................................... 223
4.1 Scope of Thermodynamics. Definitions ........................................... 223
4.2 Temperatures. Equilibria ............................................................... 225
4.3 First Law of Thermodynamics ......................................................... 228
4.4 Second Law of Thermodynamics..................................................... 231
4.5 Exergy and Anergy......................................................................... 233
4.6 Thermodynamics of Substances...................................................... 235
4.7 Changes of State of Gases and Vapors............................................. 256
4.8 Thermodynamic Processes ............................................................. 262
4.9 Ideal Gas Mixtures ......................................................................... 274
4.10 Heat Transfer ................................................................................ 280
References .............................................................................................. 293
5 Tribology
Ludger Deters .......................................................................................... 295
5.1 Tribology....................................................................................... 295
References .............................................................................................. 326
6 Design of Machine Elements
Oleg P. Lelikov ......................................................................................... 327
6.1 Mechanical Drives ......................................................................... 329
6.2 Gearings ....................................................................................... 334
6.3 Cylindrical Gearings ....................................................................... 348
6.4 Bevel Gearings .............................................................................. 364
6.5 Worm Gearings.............................................................................. 372
6.6 Design of Gear Wheels, Worm Wheels, and Worms .......................... 388
6.7 Planetary Gears ............................................................................. 399
6.8 Wave Gears ................................................................................... 412
6.9 Shafts and Axles ............................................................................ 426
6.10 Shaft–Hub Connections ................................................................. 449
6.11 Rolling Bearings ............................................................................ 460
6.12 Design of Bearing Units ................................................................. 483
6.A Appendix A ................................................................................... 516
6.B Appendix B ................................................................................... 518
References .............................................................................................. 519
7 Manufacturing Engineering
Thomas Böllinghaus, Gerry Byrne, Boris Ilich Cherpakov (deceased),
Edward Chlebus, Carl E. Cross, Berend Denkena, Ulrich Dilthey,
Takeshi Hatsuzawa, Klaus Herfurth, Horst Herold (deceased),
Andrew Kaldos, Thomas Kannengiesser, Michail Karpenko,
Bernhard Karpuschewski, Manuel Marya, Surendar K. Marya,
Klaus-Jürgen Matthes, Klaus Middeldorf, Joao Fernando G. Oliveira,
Jörg Pieschel, Didier M. Priem, Frank Riedel, Markus Schleser,
A. Erman Tekkaya, Marcel Todtermuschke, Anatole Vereschaka,
Detlef von Hofe, Nikolaus Wagner, Johannes Wodara, Klaus Woeste........... 523
7.1 Casting ......................................................................................... 525
7.2 Metal Forming............................................................................... 554
7.3 Machining Processes...................................................................... 606
7.4 Assembly, Disassembly, Joining Techniques .................................... 656
7.5 Rapid Prototyping and Advanced Manufacturing ............................ 733
7.6 Precision Machinery Using MEMS Technology................................... 768
References .............................................................................................. 773
Measuring and Quality Control
Norge I. Coello Machado, Shuichi Sakamoto, Steffen Wengler, Lutz Wisweh 787
8.1 Quality Management ..................................................................... 787
8.2 Manufacturing Measurement Technology........................................ 793
8.3 Measuring Uncertainty and Traceability .......................................... 816
8.4 Inspection Planning ...................................................................... 817
8.5 Further Reading ............................................................................ 818
9 Engineering Design
Alois Breiing, Frank Engelmann, Timothy Gutowski ................................... 819
9.1 Design Theory ............................................................................... 819
9.2 Basics ........................................................................................... 842
9.3 Precisely Defining the Task............................................................. 843
9.4 Conceptual Design ......................................................................... 845
9.5 Design .......................................................................................... 848
9.6 Design and Manufacturing for the Environment.............................. 853
9.7 Failure Mode and Effect Analysis for Capital Goods.......................... 867
References .............................................................................................. 875
10 Piston Machines
Vince Piacenti, Helmut Tschoeke, Jon H. Van Gerpen.................................. 879
10.1 Foundations of Piston Machines..................................................... 879
10.2 Positive Displacement Pumps......................................................... 893
10.3 Compressors.................................................................................. 910
10.4 Internal Combustion Engines ......................................................... 913
References .............................................................................................. 944
11 Pressure Vessels and Heat Exchangers
Ajay Mathur ............................................................................................ 947
11.1 Pressure Vessel – General Design Concepts ..................................... 947
11.2 Design of Tall Towers ..................................................................... 952
11.3 Testing Requirement ..................................................................... 953
11.4 Design Codes for Pressure Vessels ................................................... 954
11.5 Heat Exchangers............................................................................ 958
11.6 Material of Construction ................................................................ 959
References .............................................................................................. 966
12 Turbomachinery
Meinhard T. Schobeiri .............................................................................. 967
12.1 Theory of Turbomachinery Stages ................................................... 967
12.2 Gas Turbine Engines: Design and Dynamic Performance .................. 981
References .............................................................................................. 1009
13 Transport Systems
Gritt Ahrens, Torsten Dellmann, Stefan Gies, Markus Hecht, Hamid Hefazi,
Rolf Henke, Stefan Pischinger, Roger Schaufele, Oliver Tegel ...................... 1011
13.1 Overview....................................................................................... 1012
13.2 Automotive Engineering ................................................................ 1026
13.3 Railway Systems – Railway Engineering ......................................... 1070
13.4 Aerospace Engineering .................................................................. 1096
References .............................................................................................. 1144
14 Construction Machinery
Eugeniusz Budny, Mirosław Chłosta, Henning Jürgen Meyer,
Mirosław J. Skibniewski ........................................................................... 1149
14.1 Basics ........................................................................................... 1150
14.2 Earthmoving, Road Construction, and Farming Equipment .............. 1155
14.3 Machinery for Concrete Works ........................................................ 1175
14.4 Site Lifts........................................................................................ 1191
14.5 Access Machinery and Equipment .................................................. 1200
14.6 Cranes .......................................................................................... 1213
14.7 Equipment for Finishing Work........................................................ 1228
14.8 Automation and Robotics in Construction ....................................... 1238
References .............................................................................................. 1264
15 Enterprise Organization and Operation
Francesco Costanzo, Yuichi Kanda, Toshiaki Kimura, Hermann Kühnle,
Bruno Lisanti, Jagjit Singh Srai, Klaus-Dieter Thoben, Bernd Wilhelm,
Patrick M. Williams .................................................................................. 1267
15.1 Overview....................................................................................... 1268
15.2 Organizational Structures............................................................... 1271
15.3 Process Organization, Capabilities, and Supply Networks ................. 1279
15.4 Modeling and Data Structures ........................................................ 1290
15.5 Enterprise Resource Planning (ERP) ................................................ 1303
15.6 Manufacturing Execution Systems (MES).......................................... 1307
15.7 Advanced Organization Concepts.................................................... 1314
15.8 Interorganizational Structures........................................................ 1321
15.9 Organization and Communication .................................................. 1330
15.10 Enterprise Collaboration and Logistics ............................................ 1337
References .............................................................................................. 1354
Part C Complementary Material for Mechanical Engineers
16 Power Generation
Dwarkadas Kothari, P.M.V. Subbarao ....................................................... 1363
16.1 Principles of Energy Supply ............................................................ 1365
16.2 Primary Energies ........................................................................... 1367
16.3 Fuels ............................................................................................ 1367
16.4 Transformation of Primary Energy into Useful Energy ...................... 1368
16.5 Various Energy Systems and Their Conversion ................................. 1368
16.6 Direct Combustion System .............................................................. 1371
16.7 Internal Combustion Engines ......................................................... 1372
16.8 Fuel Cells ...................................................................................... 1372
16.9 Nuclear Power Stations .................................................................. 1373
16.10 Combined Power Station................................................................ 1374
16.11 Integrated Gasification Combined Cycle (IGCC) System...................... 1375
16.12 Magnetohydrodynamic (MHD) Power Generation ............................ 1378
16.13 Total-Energy Systems for Heat and Power Generation ..................... 1379
16.14 Transformation of Regenerative Energies ........................................ 1381
16.15 Solar Power Stations ...................................................................... 1382
16.16 Heat Pump.................................................................................... 1385
16.17 Energy Storage and Distribution ..................................................... 1385
16.18 Furnaces ....................................................................................... 1386
16.19 Fluidized-Bed Combustion System ................................................. 1390
16.20 Liquid-Fuel Furnace ...................................................................... 1392
16.21 Burners......................................................................................... 1392
16.22 General Furnace Accessories........................................................... 1394
16.23 Environmental Control Technology ................................................. 1396
16.24 Steam Generators .......................................................................... 1398
16.25 Parts and Components of Steam Generator ..................................... 1402
16.26 Energy Balance Analysis of a Furnace/Combustion System ............... 1406
16.27 Performance of Steam Generator ................................................... 1409
16.28 Furnace Design ............................................................................. 1409
16.29 Strength Calculations ..................................................................... 1412
16.30 Heat Transfer Calculation ............................................................... 1414
16.31 Nuclear Reactors ........................................................................... 1414
16.32 Future Prospects and Conclusion .................................................... 1418
References .............................................................................................. 1418
17 Electrical Engineering
Seddik Bacha, Jaime De La Ree, Chris Oliver Heyde, Andreas Lindemann,
Antje G. Orths, Zbigniew A. Styczynski, Jacek G. Wankowicz ....................... 1421
17.1 Fundamentals............................................................................... 1422
17.2 Transformers ................................................................................. 1442
17.3 Rotating Electrical Machines .......................................................... 1448
17.4 Power Electronics .......................................................................... 1461
17.5 Electric Drives................................................................................ 1478
17.6 Electric Power Transmission and Distribution .................................. 1487
17.7 Electric Heating ............................................................................. 1504
References .............................................................................................. 1509
18 General Tables
Stanley Baksi........................................................................................... 1511
Acknowledgements................................................................................... 1521
About the Authors..................................................................................... 1523
Detailed Contents...................................................................................... 1539
Subject Index............................................................................................. 1561