of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based Questions: In law exams, students are often given hypothetical scenarios
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
SOLUTIONS MANUAL
FUNDAMENTALS OF MODERN
MANUFACTURING:
MATERIALS,
PROCESSES, AND SYSTEMS
Second Edition
MIKELL P. GROOVER
Professor of Industrial and Manufacturing Systems Engineering
Lehigh University
John Wiley & Sons, Inc., New York
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams often blend
theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-solving and theoretical
application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and cases, and mathematics exams focus on the mastery
of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim to prepare students for professional success in their respective fields. By
understanding the structure and focus of these exams, students can better prepare for their academic and professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in
business, law, and mathematics play an essential role not only in evaluating the knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the
skills and competencies deemed necessary for professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields
like business and law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing market
conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core concepts such as financial analysis,
marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this knowledge to solve real-world problems.For example, case study-based
questions in business exams often
1
,of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based Questions: In law exams, students are often given hypothetical scenarios
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
TABLE OF CONTENTS:
Chapter Chapter Title* Page
1. Introduction (No questions or problems)
2. The Nature of Materials 4
3. Mechanical Properties of Materials (P) 7
4. Physical Properties of Materials (P) 18
5. Dimensions, Tolerances, and Surfaces 21
6. Metals (P) 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials 36
10. Fundamentals of Casting (P) 39
11. Metal Casting Processes (P) 49
12. Glassworking 57
13. Shaping Processes for Plastics (P) 60
14. Rubber Processing Technology 70
15. Shaping Processes for Polymer Matrix Composites 73
16. Powder Metallurgy (P) 76
17. Processing of Ceramics and Cermets 84
18. Fundamentals of Metal Forming (P) 87
19. Bulk Deformation Processes (P) 92
20. Sheet Metalworking (P) 112
21. Theory of Metal Machining (P) 122
22. Machining Operations and Machine Tools (P) 134
23. Cutting Tool Technology (P) 142
24. Economic and Product Design Considerations in Machining (P) 153
25. Grinding and Other Abrasive Processes (P) 166
26. Nontraditional Machining and Thermal Cutting Processes (P) 173
27. Heat Treatment of Metals 180
28. Cleaning and Surface Treatments 182
29. Coating and Deposition Processes (P) 184
30. Fundamentals of Welding (P) 190
31. Welding Processes (P) 197
32. Brazing, Soldering, and Adhesive Bonding 207
33. Mechanical Assembly (P) 211
34. Rapid Prototyping (P) 218
35. Processing of Integrated Circuits (P) 222
36. Electronics Assembly and Packaging 230
37. Microfabrication Technologies 233
38. Numerical Control and Industrial Robotics (P) 235
39. Group Technology and Flexible Manufacturing Systems 244
40. Production Lines (P) 246
41. Manufacturing Engineering 253
42. Production Planning and Control (P) 256
43. Quality Control (P) 263
44. Measurement and Inspection 271
*(P) indicates chapters with problem sets.
2
,2 THE NATURE OF MATERIALS
Review Questions
2.1 The elements listed in the Periodic Table can be divided into three categories. What are these
categories and give an example of each?
Answer. The three types of elements are metals (e.g., aluminum), nonmetals (e.g., oxygen), and
semimetals (e.g., silicon). of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based
Questions: In law exams, students are often given hypothetical scenarios (problem questions) and are asked to analyze the legal issues involved. These require students to apply
2.2 Which elements are the noble metals?
Answer. The noble metals are copper, silver, and gold.
2.3 What is the difference between primary and secondary bonding in the structure of materials?
Answer. Primary bonding is strong bonding between atoms in a material, for example to form a
molecule; while secondary bonding is not as strong and is associated with attraction between
molecules in the material.
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams
often blend theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-
solving and theoretical application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and
cases, and mathematics exams focus on the mastery of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim
to prepare students for professional success in their respective fields. By understanding the structure and focus of these exams, students can better prepare for their academic and
professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in business, law, and mathematics play an essential role not only in evaluating the
knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the skills and competencies deemed necessary for
professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields like business and
law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing
market conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core
concepts such as financial analysis, marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this
knowledge to solve real-world problems.For example, case study-based questions in business exams often
2.4 Describe how ionic bonding works?
Answer. In ionic bonding, atoms of one element give up their outer electron(s) to the atoms of
another element to form complete outer shells.
2.5 What is the difference between crystalline and noncrystalline structures in materials?
Answer. The atoms in a crystalline structure are located at regular and repeating lattice positions in
three dimensions; thus, the crystal structure possesses a long-range order which allows a high
packing density. The atoms in a noncrystalline structure are randomly positioned in the material, not
possessing any repeating, regular pattern.
2.6 What are some common point defects in a crystal lattice structure?
Answer. Some of the common point defects are: (1) vacancy - a missing atom in the lattice
structure; (2) ion-pair vacancy (Schottky defect) - a missing pair of ions of opposite charge in a
compound; (3) interstitialcy - a distortion in the lattice caused by an extra atom present; and (4)
Frenkel defect - an ion is removed from a regular position in the lattice and inserted into an
interstitial position not normally occupied by such an ion.
2.7 Define the difference between elastic and plastic deformation in terms of the effect on the crystal
lattice structure.
Answer. Elastic deformation involves a temporary distortion of the lattice structure that is
proportional to the applied stress. Plastic deformation involves a stress of sufficient magnitude to
cause a permanent shift in the relative positions of adjacent atoms in the lattice. Plastic deformation
generally involves the mechanism of slip - relative movement of atoms on opposite sides of a plane
in the lattice.
3
, 2.8 How do grain boundaries contribute to the strain hardening phenomenon in metals?
Answer. Grain boundaries block the continued movement of dislocations in the metal during
straining. As more dislocations become blocked, the metal becomes more difficult to deform; in
effect it becomes stronger.
2.9 Identify some materials that have a crystalline structure.
of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based Questions: In law exams, students are often given hypothetical scenarios
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
Answer. Materials typically possessing a crystalline structure are metals and ceramics other than
glass. Some plastics have a partially crystalline structure.
2.10 Identify some materials that possess a noncrystalline structure.
Answer. Materials typically having a noncrystalline structure include glass (fused silica), rubber,
and certain plastics (specifically, thermosetting plastics).
2.11 What is the basic difference in the solidification (or melting) process between crystalline and
noncrystalline structures?
Answer. Crystalline structures undergo an abrupt volumetric change as they transform from liquid
to solid state and vice versa. This is accompanied by an amount of energy called the heat of fusion
that must be added to the material during melting or released during solidification. Noncrystalline
materials melt and solidify without the abrupt volumetric change and heat of fusion.
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams
often blend theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-
solving and theoretical application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and
cases, and mathematics exams focus on the mastery of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim
to prepare students for professional success in their respective fields. By understanding the structure and focus of these exams, students can better prepare for their academic and
professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in business, law, and mathematics play an essential role not only in evaluating the
knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the skills and competencies deemed necessary for
professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields like business and
law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing
market conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core
concepts such as financial analysis, marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this
knowledge to solve real-world problems.For example, case study-based questions in business exams often
Multiple Choice Quiz
There are a total of 20 correct answers in the following multiple choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be
given, since each correct answer is worth 1 point. For each question, each omitted answer or wrong
answer reduces the score by 1 point, and each additional answer beyond the number of answers required
reduces the score by 1 point. Percentage score on the quiz is based on the total number of correct
answers.
2.1 The basic structural unit of matter is which one of the following? (a) atom, (b) electron, (c) element,
(d) molecule, or (e) nucleus.
Answer. (a)
2.2 Approximately how many different elements have been identified (one answer)? (a) 10, (b) 50, (c)
100, (d) 200, or (e) 500.
Answer. (c)
2.3 In the Periodic Table, the elements can be divided into which of the following categories (more than
one)? (a) ceramics, (b) gases, (c) liquids, (d) metals, (e) nonmetals, (f) polymers, (g) semi-metals,
and (h) solids.
Answer. (d), (e), and (g).
2.4 The element with the lowest density and smallest atomic weight is which one of the following? (a)
4
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
SOLUTIONS MANUAL
FUNDAMENTALS OF MODERN
MANUFACTURING:
MATERIALS,
PROCESSES, AND SYSTEMS
Second Edition
MIKELL P. GROOVER
Professor of Industrial and Manufacturing Systems Engineering
Lehigh University
John Wiley & Sons, Inc., New York
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams often blend
theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-solving and theoretical
application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and cases, and mathematics exams focus on the mastery
of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim to prepare students for professional success in their respective fields. By
understanding the structure and focus of these exams, students can better prepare for their academic and professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in
business, law, and mathematics play an essential role not only in evaluating the knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the
skills and competencies deemed necessary for professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields
like business and law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing market
conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core concepts such as financial analysis,
marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this knowledge to solve real-world problems.For example, case study-based
questions in business exams often
1
,of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based Questions: In law exams, students are often given hypothetical scenarios
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
TABLE OF CONTENTS:
Chapter Chapter Title* Page
1. Introduction (No questions or problems)
2. The Nature of Materials 4
3. Mechanical Properties of Materials (P) 7
4. Physical Properties of Materials (P) 18
5. Dimensions, Tolerances, and Surfaces 21
6. Metals (P) 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials 36
10. Fundamentals of Casting (P) 39
11. Metal Casting Processes (P) 49
12. Glassworking 57
13. Shaping Processes for Plastics (P) 60
14. Rubber Processing Technology 70
15. Shaping Processes for Polymer Matrix Composites 73
16. Powder Metallurgy (P) 76
17. Processing of Ceramics and Cermets 84
18. Fundamentals of Metal Forming (P) 87
19. Bulk Deformation Processes (P) 92
20. Sheet Metalworking (P) 112
21. Theory of Metal Machining (P) 122
22. Machining Operations and Machine Tools (P) 134
23. Cutting Tool Technology (P) 142
24. Economic and Product Design Considerations in Machining (P) 153
25. Grinding and Other Abrasive Processes (P) 166
26. Nontraditional Machining and Thermal Cutting Processes (P) 173
27. Heat Treatment of Metals 180
28. Cleaning and Surface Treatments 182
29. Coating and Deposition Processes (P) 184
30. Fundamentals of Welding (P) 190
31. Welding Processes (P) 197
32. Brazing, Soldering, and Adhesive Bonding 207
33. Mechanical Assembly (P) 211
34. Rapid Prototyping (P) 218
35. Processing of Integrated Circuits (P) 222
36. Electronics Assembly and Packaging 230
37. Microfabrication Technologies 233
38. Numerical Control and Industrial Robotics (P) 235
39. Group Technology and Flexible Manufacturing Systems 244
40. Production Lines (P) 246
41. Manufacturing Engineering 253
42. Production Planning and Control (P) 256
43. Quality Control (P) 263
44. Measurement and Inspection 271
*(P) indicates chapters with problem sets.
2
,2 THE NATURE OF MATERIALS
Review Questions
2.1 The elements listed in the Periodic Table can be divided into three categories. What are these
categories and give an example of each?
Answer. The three types of elements are metals (e.g., aluminum), nonmetals (e.g., oxygen), and
semimetals (e.g., silicon). of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based
Questions: In law exams, students are often given hypothetical scenarios (problem questions) and are asked to analyze the legal issues involved. These require students to apply
2.2 Which elements are the noble metals?
Answer. The noble metals are copper, silver, and gold.
2.3 What is the difference between primary and secondary bonding in the structure of materials?
Answer. Primary bonding is strong bonding between atoms in a material, for example to form a
molecule; while secondary bonding is not as strong and is associated with attraction between
molecules in the material.
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams
often blend theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-
solving and theoretical application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and
cases, and mathematics exams focus on the mastery of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim
to prepare students for professional success in their respective fields. By understanding the structure and focus of these exams, students can better prepare for their academic and
professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in business, law, and mathematics play an essential role not only in evaluating the
knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the skills and competencies deemed necessary for
professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields like business and
law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing
market conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core
concepts such as financial analysis, marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this
knowledge to solve real-world problems.For example, case study-based questions in business exams often
2.4 Describe how ionic bonding works?
Answer. In ionic bonding, atoms of one element give up their outer electron(s) to the atoms of
another element to form complete outer shells.
2.5 What is the difference between crystalline and noncrystalline structures in materials?
Answer. The atoms in a crystalline structure are located at regular and repeating lattice positions in
three dimensions; thus, the crystal structure possesses a long-range order which allows a high
packing density. The atoms in a noncrystalline structure are randomly positioned in the material, not
possessing any repeating, regular pattern.
2.6 What are some common point defects in a crystal lattice structure?
Answer. Some of the common point defects are: (1) vacancy - a missing atom in the lattice
structure; (2) ion-pair vacancy (Schottky defect) - a missing pair of ions of opposite charge in a
compound; (3) interstitialcy - a distortion in the lattice caused by an extra atom present; and (4)
Frenkel defect - an ion is removed from a regular position in the lattice and inserted into an
interstitial position not normally occupied by such an ion.
2.7 Define the difference between elastic and plastic deformation in terms of the effect on the crystal
lattice structure.
Answer. Elastic deformation involves a temporary distortion of the lattice structure that is
proportional to the applied stress. Plastic deformation involves a stress of sufficient magnitude to
cause a permanent shift in the relative positions of adjacent atoms in the lattice. Plastic deformation
generally involves the mechanism of slip - relative movement of atoms on opposite sides of a plane
in the lattice.
3
, 2.8 How do grain boundaries contribute to the strain hardening phenomenon in metals?
Answer. Grain boundaries block the continued movement of dislocations in the metal during
straining. As more dislocations become blocked, the metal becomes more difficult to deform; in
effect it becomes stronger.
2.9 Identify some materials that have a crystalline structure.
of legal statutes, case law, and their ability to apply legal reasoning. Common types of law exams include:Essay/Problem-Based Questions: In law exams, students are often given hypothetical scenarios
(problem questions) and are asked to analyze the legal issues involved. These require students to apply
Answer. Materials typically possessing a crystalline structure are metals and ceramics other than
glass. Some plastics have a partially crystalline structure.
2.10 Identify some materials that possess a noncrystalline structure.
Answer. Materials typically having a noncrystalline structure include glass (fused silica), rubber,
and certain plastics (specifically, thermosetting plastics).
2.11 What is the basic difference in the solidification (or melting) process between crystalline and
noncrystalline structures?
Answer. Crystalline structures undergo an abrupt volumetric change as they transform from liquid
to solid state and vice versa. This is accompanied by an amount of energy called the heat of fusion
that must be added to the material during melting or released during solidification. Noncrystalline
materials melt and solidify without the abrupt volumetric change and heat of fusion.
exams demanding precise solutions, all require students to structure their responses effectively.However, key differences emerge in the nature of the assessments. Business exams
often blend theory with practical decision-making, law exams rely on legal reasoning and precedent, and mathematics exams emphasize problem-solving and technical
skills.________________________________________ConclusionExams in business, law, and mathematics each test different skill sets, from analytical reasoning to problem-
solving and theoretical application. Business exams challenge students to apply their knowledge to real-world situations, law exams require detailed analysis of legal principles and
cases, and mathematics exams focus on the mastery of concepts and the ability to solve complex problems. While each discipline has its own unique approach to assessment, all aim
to prepare students for professional success in their respective fields. By understanding the structure and focus of these exams, students can better prepare for their academic and
professional journeys.5. The Role of Exams in Business, Law, and Mathematics EducationExams in business, law, and mathematics play an essential role not only in evaluating the
knowledge of students but also in shaping their skills for future careers. In each field, the way exams are structured reflects the skills and competencies deemed necessary for
professional success. These exams test not only theoretical understanding but also the practical application of knowledge, which is particularly crucial for fields like business and
law.5.1. The Role of Business ExamsBusiness exams prepare students to face the challenges of a rapidly changing global economy. The ability to think critically, adapt to changing
market conditions, and make data-driven decisions is crucial in business. Exams in business schools serve multiple purposes. First, they assess whether students understand core
concepts such as financial analysis, marketing strategies, and organizational behavior. More importantly, business exams are designed to test whether students can apply this
knowledge to solve real-world problems.For example, case study-based questions in business exams often
Multiple Choice Quiz
There are a total of 20 correct answers in the following multiple choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be
given, since each correct answer is worth 1 point. For each question, each omitted answer or wrong
answer reduces the score by 1 point, and each additional answer beyond the number of answers required
reduces the score by 1 point. Percentage score on the quiz is based on the total number of correct
answers.
2.1 The basic structural unit of matter is which one of the following? (a) atom, (b) electron, (c) element,
(d) molecule, or (e) nucleus.
Answer. (a)
2.2 Approximately how many different elements have been identified (one answer)? (a) 10, (b) 50, (c)
100, (d) 200, or (e) 500.
Answer. (c)
2.3 In the Periodic Table, the elements can be divided into which of the following categories (more than
one)? (a) ceramics, (b) gases, (c) liquids, (d) metals, (e) nonmetals, (f) polymers, (g) semi-metals,
and (h) solids.
Answer. (d), (e), and (g).
2.4 The element with the lowest density and smallest atomic weight is which one of the following? (a)
4
