In recognition of his outstanding contribution to tribology in metal cutting and its effect on the manufacturing system.
Friction plays a crucial role in the cutting process – Dr Merchant’s theory of adhesive friction published in 1940 and 1941, succeeded in combining the two different theories of friction which had been upheld by the scientists since 1785. His theory on cutting published in 1944 and 1945 imbued the whole field of machine tools research with a new fundamental approach, gradually replacing the empirical tradition, used in machine tools up to that time. Merchant’s influence emphasised enquiry and research into the understanding of the basis of practical process. In the field of metal cutting, his original concept of the basic mechanism of metal cutting process may be considered to be the cornerstone upon which has been built the presently accepted theory of metal cutting.
Eugene Merchant gave a tremendous fillip to the detailed study of cutting forces, involved in action between the chip and the tool, setting in motion a trend which influenced a whole generation of workers. This trend has led to the widening of the tribologically inspired technology of metal cutting into the area of production systems as a whole.
Dr Merchant joined the Cincinnati Milling Machine Company (now Cincinnati Milacron) in 1936 as a Research Fellow at the University of Cincinnati. He served as a Research Physicist (1940-1948), Senior Research Physicist (1948-1951), Assistant Director for Research (1951-1957), Director of Physical Research (1957-1963), Director of Scientific Research (1963-1969), now Director of Research Planning of Cincinnati in which position he is still engaged, albeit in a supervisory capacity, in the furtherance of tribological research.
As a Research Physicist, his earliest research work in tribology was on the mechanism of static friction and on the surface friction of clean metals, followed by the work for which he became best known, viz: the mechanics of metal cutting. This led to studies of machineability and of cutting fluid action and measurement of tool wear, including the use of radioactive cutting tools.
In many of his endeavours he was partnered by Hans Ernst, his guide and mentor, who initiated and helped in the direction of much of his early research work, and later by E J Krabaler and other notable workers. Pursuing the research of the concept he had created, with his colleagues he developed the whole area of tribology in metal cutting and with it the stimulation throughout the production world, of a more scientific and technological aspect of metal cutting. Future generations may well consider this successful stimulation to have been his greatest achievement.
In 1957 in his thesis “Production Research of Metal Cutting”, he stressed the importance of unified (or system) type approach to metal cutting research, from which followed “the manufacturing concept” as announced to CIRP in 1961.
In those early days, few production engineering research workers had begun to realise that the machine tools, cutting and grinding metal, were only small parts of the production process. Research was diversified into assembly, joining and finishing processes. Merchant formalised this trend towards diversification by insisting that production should be considered as part of the entire manufacturing system, that real productive gains were not to be made merely by developing new and faster metal removing methods, but rather by optimising the entire production process. Thus, he widened the field from the tribological interface of a cutting tool and the metal, towards the whole system of production. This theme became the main preoccupation for many years and brought him renewed distinction.
Effectively, Dr Merchant has never lost tough with the scientific and technological aspects of tribology, whether by instituting or supervising research, or by the promotion of organised tribology in various forms. His recent activities in tribology included that of Chairman of a U.S. Department of Energy panel on Industrial Machinery & Processes which defined projects that could reduce U.S. Energy consumption by several percentage points. Another outstanding contribution by Dr Merchant has been his participation in programmes for the National Research Council, in which, at his insistence, emphasis on the tribology of metal cutting was included.
In response to U.S. Government initiatives to improve productivity, a National Tribology Center has been proposed and is likely to be established shortly; one of three principal areas for initial focus will be “manufacturing systems” – the primary author of that tribology programme was Dr Merchant.
Dr Merchant is the recipient of many honours including the American Society of Mechanical Engineers Richards Memorial Award (1959), the American Society of Lubrication Engineers National Award (1959), the Society of Manufacturing Engineers Research Medal (1968), Distinguished Alumnus Award of the University of Cincinnati (1969). He is an Honorary Member of the American Society of Mechanical Engineers, a Past National President of the American Society of Lubrication Engineers and of the American Society of Manufacturing Engineers, a Past Vice President of the American Society of Mechanical Engineers, a Fellow of the American Society for Metals, and was a President of the International Institution of Production Engineers in Research in 1968/69. He is an Honorary Doctor of Science of the Universities of Vermont (USA) and Salford (England), a member of the National Academy of Engineering and also Dr Merchant was the first recipient (1980) of the newly established George Schlesinger Prize of the City of Berlin.
A pioneer, an enlightened human being, his career has been characterised by determination, with a missionary zeal he widened the areas of tribology of metal cutting, then widened it into production systems and returned to tribology in the area of national economy, in particular, to the relationship of tribology, energy and manufacture. He has rightly been called one of the fathers of real tribology in the United States.
For the totality of his outstanding tribological achievements, ranging over nearly 40 years, Dr Mylon Eugene Merchant is awarded the Tribology Gold Medal for 1980.