SOLUTION MANUAL FOR Fundamentals of Modern Manufacturing: Materials, Processes, and Systems 2nd Edition by Mikell P. Groover ISBN: 978-0471400516 COMPLETE GUIDE ALL CHAPTERS COVERED 100% VERIFIED A+ GRADE ASSURED!!!!!NEW LATEST UPDATE!!!!!

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,TABLE OF CONTENTS:
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Chapter Chapter Title* dt Page
1. Introduction (No questions or problems) dt dt dt dt



2. The Nature of Materials
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3. Mechanical Properties of Materials (P) dt dt dt dt 7
4. Physical Properties of Materials (P) dt dt dt dt 18
5. Dimensions, Tolerances, and Surfaces dt dt dt 21
6. Metals (P) dt 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials dt 36
10. Fundamentals of Casting (P) dt dt dt 39
11. Metal Casting Processes (P)
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12. Glassworking 57
13. Shaping Processes for Plastics (P)dt dt dt dt 60
14. Rubber Processing Technologydt dt 70
15. Shaping Processes for Polymer Matrix Composites
dt dt dt dt dt 73
16. Powder Metallurgy (P) dt dt 76
17. Processing of Ceramics and Cermets dt dt dt dt 84
18. Fundamentals of Metal Forming (P) dt dt dt dt 87
19. Bulk Deformation Processes (P)
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20. Sheet Metalworking (P)
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21. Theory of Metal Machining (P)
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22. Machining Operations and Machine Tools (P) dt dt dt dt dt 134
23. Cutting Tool Technology (P) dt dt dt 142
24. Economic and Product Design Considerations in Machining (P)
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25. Grinding and Other Abrasive Processes (P) dt dt dt dt dt 166
26. Nontraditional Machining and Thermal Cutting Processes (P) dt dt dt dt dt dt 173
27. Heat Treatment of Metals
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28. Cleaning and Surface Treatments dt dt dt 182
29. Coating and Deposition Processes (P)
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30. Fundamentals of Welding (P) dt dt dt 190
31. Welding Processes (P) dt dt 197
32. Brazing, Soldering, and Adhesive Bonding
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33. Mechanical Assembly (P) dt dt 211
34. Rapid Prototyping (P)
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35. Processing of Integrated Circuits (P) dt dt dt dt 222
36. Electronics Assembly and Packaging dt dt dt 230
37. Microfabrication Technologies dt 233
38. Numerical Control and Industrial Robotics (P) dt dt dt dt dt 235
39. Group Technology and Flexible Manufacturing Systems
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40. Production Lines (P) dt dt 246
41. Manufacturing Engineering dt 253
42. Production Planning and Control (P) dt dt dt dt 256
43. Quality Control (P) dt dt 263
44. Measurement and Inspection dt dt 271

*(P) indicates chapters with problem sets.
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2

,2 THE NATURE OF MATERIALS dt dt dt




Review Questionsdt




2.1 The elements listed in the Periodic Table can be divided into three categories. What are these c
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ategories and give an example of each? dt dt dt dt dt dt




Answer. The three types of elements are metals (e.g., aluminum), nonmetals (e.g., oxygen), and semimet
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als (e.g., silicon).
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2.2 Which elements are the noble metals? dt dt dt dt dt




Answer. The noble metals are copper, silver, and gold. dt dt dt dt dt dt dt dt




2.3 What is the difference between primary and secondary bonding in the structure of materials?
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Answer. Primary bonding is strong bonding between atoms in a material, for example to form a molec
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ule; while secondary bonding is not as strong and is associated with attraction between molecules in
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the material. dt




2.4 Describe how ionic bonding works? dt dt dt dt




Answer. In ionic bonding, atoms of one element give up their outer electron(s) to the atoms of another
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element to form complete outer shells.
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2.5 What is the difference between crystalline and noncrystalline structures in materials?
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Answer. The atoms in a crystalline structure are located at regular and repeating lattice positions in t
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hree dimensions; thus, the crystal structure possesses a long-
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range order which allows a high packing density. The atoms in a noncrystalline structure are randoml
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y positioned in the material, not possessing any repeating, regular pattern.
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2.6 What are some common point defects in a crystal lattice structure?
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Answer. Some of the common point defects are: (1) vacancy -dt dt dt dt dt dt dt dt dt dt



a missing atom in the lattice structure; (2) ion-pair vacancy (Schottky defect) -
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a missing pair of ions of opposite charge in a compound; (3) interstitialcy -
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a distortion in the lattice caused by an extra atom present; and (4) Frenkel defect -
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an ion is removed from a regular position in the lattice and inserted into an interstitial position not no
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rmally occupied by such an ion. dt dt dt dt dt




2.7 Define the difference between elastic and plastic deformation in terms of the effect on the crystal la
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ttice structure. dt




Answer. Elastic deformation involves a temporary distortion of the lattice structure that is proportio
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nal to the applied stress. Plastic deformation involves a stress of sufficient magnitude to cause a per
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manent shift in the relative positions of adjacent atoms in the lattice. Plastic deformation generally in
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volves the mechanism of slip - relative movement of atoms on opposite sides of a plane in the lattice.
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2.8 How do grain boundaries contribute to the strain hardening phenomenon in metals?
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Answer. Grain boundaries block the continued movement of dislocations in the metal during strainin
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g. As more dislocations become blocked, the metal becomes more difficult to deform; in effect it beco
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mes stronger. dt




2.9 Identify some materials that have a crystalline structure.
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, Answer. Materials typically possessing a crystalline structure are metals and ceramics other than gla
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ss. Some plastics have a partially crystalline structure.
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2.10 Identify some materials that possess a noncrystalline structure.
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Answer. Materials typically having a noncrystalline structure include glass (fused silica), rubber, and
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certain plastics (specifically, thermosetting plastics).
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2.11 What is the basic difference in the solidification (or melting) process between crystalline and n
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oncrystalline structures? dt




Answer. Crystalline structures undergo an abrupt volumetric change as they transform from liquid to
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solid state and vice versa. This is accompanied by an amount of energy called the heat of fusion that
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must be added to the material during melting or released during solidification. Noncrystalline materi
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als melt and solidify without the abrupt volumetric change and heat of fusion.
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Multiple Choice Quiz dt dt




There are a total of 20 correct answers in the following multiple choice questions (some questions have m
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ultiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given, si
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nce each correct answer is worth 1 point. For each question, each omitted answer or wrong answer reduce
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s the score by 1 point, and each additional answer beyond the number of answers required reduces the scor
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e by 1 point. Percentage score on the quiz is based on the total number of correct answers.
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2.1 The basic structural unit of matter is which one of the following? (a) atom, (b) electron, (c) element,
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(d) molecule, or (e) nucleus.
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Answer. (a) d t




2.2 Approximately how many different elements have been identified (one answer)? (a) 10, (b) 50, (c) 1 dt dt dt dt dt dt dt dt dt dt dt dt dt dt dt



00, (d) 200, or (e) 500.
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Answer. (c) d t




2.3 In the Periodic Table, the elements can be divided into which of the following categories (more than on
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e)? (a) ceramics, (b) gases, (c) liquids, (d) metals, (e) nonmetals, (f) polymers, (g) semi-
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metals, and (h) solids. dt dt dt




Answer. (d), (e), and (g). dt dt dt dt




2.4 The element with the lowest density and smallest atomic weight is which one of the following? (a) alu
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minum, (b) argon, (c) helium, (d) hydrogen, or (e) magnesium.
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Answer. (d) d t




2.5 Which of the following bond types are classified as primary bonds (more than one)? (a) covalent bon
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ding, (b) hydrogen bonding, (c) ionic bonding, (d) metallic bonding, and (e) van der Waals forces.
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Answer. (a), (c), and (d). dt dt dt dt




2.6 How many atoms are there in the unit cell of the face-
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centered cubic (FCC) unit cell (one answer)? (a) 8, (b) 9, (c) 10, (d) 12, or (e) 14.
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Answer. (e) d t




2.7 Which of the following are not point defects in a crystal lattice structure (more than one)? (a) edge di
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slocation, (b) interstitialcy, (c) Schottky defect, or (d) vacancy.
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