1
, SOLUTIONS MANUAL cn
FUNDAMENTALSOFMODE cn cn
RN MANUFACTURING:
cn
MATERIALS, PROCESSES, AND SYSTEMS c n c n c n
Second Edition cn
MIKELL P. GROOVER
cn cn
Professor of Industrial and Manufacturing Systems Engineering Lehigh
cn cn cn cn cn cn cn cn
University
John Wiley & Sons, Inc., New York
cn cn cn cn cn cn cn
2
,PREFACE
This is the Solutions Manual for the textbook Fundamentals of Modern Manufacturing: Materia
cn cn cn cn cn cn cn cn cn cn cn cn
ls, Processes, and Systems (Second Edition). It contains the answers to the Review Questions and
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
Multiple Choice Quizzes at the end of the Chapters 2 through 44, as well as the Problems at the end of
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
Chapters 3, 4, 6, 10, 11, 13, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 29, 30,
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
31, 33, 34, 35, 38, 40, 42, and 43. There are approximately 740 review questions, 500 quiz questions, a
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
nd 500 problems (nearly all of them quantitative) in the text.
cn cn cn cn cn cn cn cn cn cn
I have personally answered all of the questions and solved all of the quizzes and problems and have per
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
sonally recorded the solutions in this booklet. Many of the problems have been tested in class, thus givi
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
ng me an opportunity to compare my own answers with those developed by the students. Despite my b
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
est efforts to avoid errors in this solutions manual, I am sure that errors are present. I would appreciate
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
hearing from those of you who discover these errors, so that I can make the necessary corrections in s
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
ubsequent editions of the Solutions Manual. Similarly, I would appreciate any suggestions from users
cn cn cn cn cn cn cn cn cn cn cn cn cn cn
of the text itself that might help to make any subsequent editions more accurate, more relevant, and easie
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
r to use. My address is:
cn cn cn cn cn
Dr. Mikell P. Groovercn cn cn
Department of Industrial and Manufacturing Systems Engineering L cn cn cn cn cn cn cn
ehigh University cn
200 West Packer Avenue Bethlehe
cn cn cn cn
m, PA 18015 cn cn
Office telephone number 610-758- cn cn cn
4030. Fax machine number 610-758- cn cn cn cn
4886.
E-
mail addresses: either Mikell.
cn cn cn
or cn
u
I hope you find the text and this Solutions Manual to be helpful teaching aids in your particular manu
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
facturing course. cn
Mikell P. Groover cn cn
3
, TABLE OF CONTENTS:
cn cn
Chapter Chapter Title* cn Page
1. Introduction (No questions or problems) cn cn cn cn
2. The Nature of Materials
cn cn cn 4
3. Mechanical Properties of Materials (P) cn cn cn cn 7
4. Physical Properties of Materials (P)
cn cn cn cn 18
5. Dimensions, Tolerances, and Surfaces cn cn cn 21
6. Metals (P) cn 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials cn 36
10. Fundamentals of Casting (P) cn cn cn 39
11. Metal Casting Processes (P)
cn cn cn 49
12. Glassworking 57
13. Shaping Processes for Plastics (P)
cn cn cn cn 60
14. Rubber Processing Technology
cn cn 70
15. Shaping Processes for Polymer Matrix Composites
cn cn cn cn cn 73
16. Powder Metallurgy (P) cn cn 76
17. Processing of Ceramics and Cermets cn cn cn cn 84
18. Fundamentals of Metal Forming (P) cn cn cn cn 87
19. Bulk Deformation Processes (P)
cn cn cn 92
20. Sheet Metalworking (P)
cn cn 112
21. Theory of Metal Machining (P)
cn cn cn cn 122
22. Machining Operations and Machine Tools (P) cn cn cn cn cn 134
23. Cutting Tool Technology (P)
cn cn cn 142
24. Economic and Product Design Considerations in Machining (P)
cn cn cn cn cn cn cn 153
25. Grinding and Other Abrasive Processes (P)
cn cn cn cn cn 166
26. Nontraditional Machining and Thermal Cutting Processes (P) cn cn cn cn cn cn 173
27. Heat Treatment of Metals
cn cn cn 180
28. Cleaning and Surface Treatments cn cn cn 182
29. Coating and Deposition Processes (P)
cn cn cn cn 184
30. Fundamentals of Welding (P) cn cn cn 190
31. Welding Processes (P) cn cn 197
32. Brazing, Soldering, and Adhesive Bonding
cn cn cn cn 207
33. Mechanical Assembly (P) cn cn 211
34. Rapid Prototyping (P)
cn cn 218
35. Processing of Integrated Circuits (P) cn cn cn cn 222
36. Electronics Assembly and Packaging cn cn cn 230
37. Microfabrication Technologies cn 233
38. Numerical Control and Industrial Robotics (P) cn cn cn cn cn 235
39. Group Technology and Flexible Manufacturing Systems
cn cn cn cn cn 244
40. Production Lines (P) cn cn 246
41. Manufacturing Engineering cn 253
42. Production Planning and Control (P) cn cn cn cn 256
43. Quality Control (P) cn cn 263
44. Measurement and Inspection cn cn 271
*(P) indicates chapters with problem sets.
cn cn cn cn cn
4
, SOLUTIONS MANUAL cn
FUNDAMENTALSOFMODE cn cn
RN MANUFACTURING:
cn
MATERIALS, PROCESSES, AND SYSTEMS c n c n c n
Second Edition cn
MIKELL P. GROOVER
cn cn
Professor of Industrial and Manufacturing Systems Engineering Lehigh
cn cn cn cn cn cn cn cn
University
John Wiley & Sons, Inc., New York
cn cn cn cn cn cn cn
2
,PREFACE
This is the Solutions Manual for the textbook Fundamentals of Modern Manufacturing: Materia
cn cn cn cn cn cn cn cn cn cn cn cn
ls, Processes, and Systems (Second Edition). It contains the answers to the Review Questions and
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
Multiple Choice Quizzes at the end of the Chapters 2 through 44, as well as the Problems at the end of
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
Chapters 3, 4, 6, 10, 11, 13, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 29, 30,
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
31, 33, 34, 35, 38, 40, 42, and 43. There are approximately 740 review questions, 500 quiz questions, a
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
nd 500 problems (nearly all of them quantitative) in the text.
cn cn cn cn cn cn cn cn cn cn
I have personally answered all of the questions and solved all of the quizzes and problems and have per
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
sonally recorded the solutions in this booklet. Many of the problems have been tested in class, thus givi
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
ng me an opportunity to compare my own answers with those developed by the students. Despite my b
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
est efforts to avoid errors in this solutions manual, I am sure that errors are present. I would appreciate
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
hearing from those of you who discover these errors, so that I can make the necessary corrections in s
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
ubsequent editions of the Solutions Manual. Similarly, I would appreciate any suggestions from users
cn cn cn cn cn cn cn cn cn cn cn cn cn cn
of the text itself that might help to make any subsequent editions more accurate, more relevant, and easie
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
r to use. My address is:
cn cn cn cn cn
Dr. Mikell P. Groovercn cn cn
Department of Industrial and Manufacturing Systems Engineering L cn cn cn cn cn cn cn
ehigh University cn
200 West Packer Avenue Bethlehe
cn cn cn cn
m, PA 18015 cn cn
Office telephone number 610-758- cn cn cn
4030. Fax machine number 610-758- cn cn cn cn
4886.
E-
mail addresses: either Mikell.
cn cn cn
or cn
u
I hope you find the text and this Solutions Manual to be helpful teaching aids in your particular manu
cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn cn
facturing course. cn
Mikell P. Groover cn cn
3
, TABLE OF CONTENTS:
cn cn
Chapter Chapter Title* cn Page
1. Introduction (No questions or problems) cn cn cn cn
2. The Nature of Materials
cn cn cn 4
3. Mechanical Properties of Materials (P) cn cn cn cn 7
4. Physical Properties of Materials (P)
cn cn cn cn 18
5. Dimensions, Tolerances, and Surfaces cn cn cn 21
6. Metals (P) cn 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials cn 36
10. Fundamentals of Casting (P) cn cn cn 39
11. Metal Casting Processes (P)
cn cn cn 49
12. Glassworking 57
13. Shaping Processes for Plastics (P)
cn cn cn cn 60
14. Rubber Processing Technology
cn cn 70
15. Shaping Processes for Polymer Matrix Composites
cn cn cn cn cn 73
16. Powder Metallurgy (P) cn cn 76
17. Processing of Ceramics and Cermets cn cn cn cn 84
18. Fundamentals of Metal Forming (P) cn cn cn cn 87
19. Bulk Deformation Processes (P)
cn cn cn 92
20. Sheet Metalworking (P)
cn cn 112
21. Theory of Metal Machining (P)
cn cn cn cn 122
22. Machining Operations and Machine Tools (P) cn cn cn cn cn 134
23. Cutting Tool Technology (P)
cn cn cn 142
24. Economic and Product Design Considerations in Machining (P)
cn cn cn cn cn cn cn 153
25. Grinding and Other Abrasive Processes (P)
cn cn cn cn cn 166
26. Nontraditional Machining and Thermal Cutting Processes (P) cn cn cn cn cn cn 173
27. Heat Treatment of Metals
cn cn cn 180
28. Cleaning and Surface Treatments cn cn cn 182
29. Coating and Deposition Processes (P)
cn cn cn cn 184
30. Fundamentals of Welding (P) cn cn cn 190
31. Welding Processes (P) cn cn 197
32. Brazing, Soldering, and Adhesive Bonding
cn cn cn cn 207
33. Mechanical Assembly (P) cn cn 211
34. Rapid Prototyping (P)
cn cn 218
35. Processing of Integrated Circuits (P) cn cn cn cn 222
36. Electronics Assembly and Packaging cn cn cn 230
37. Microfabrication Technologies cn 233
38. Numerical Control and Industrial Robotics (P) cn cn cn cn cn 235
39. Group Technology and Flexible Manufacturing Systems
cn cn cn cn cn 244
40. Production Lines (P) cn cn 246
41. Manufacturing Engineering cn 253
42. Production Planning and Control (P) cn cn cn cn 256
43. Quality Control (P) cn cn 263
44. Measurement and Inspection cn cn 271
*(P) indicates chapters with problem sets.
cn cn cn cn cn
4