SOLUTIONS MANUAL r
FUNDAMENTALSOF r r
MODERN MANUFAC r
TURING:
MATERIALS, PROCESSES, AND SYSTEMS
r r r
Second Edition r
MIKELL P. GROOVER
r r
Professor of Industrial and Manufacturing Systems EngineeringLehig
r r r r r r r
h University
r
John Wiley & Sons, Inc., New York
r r r r r r
1
,PREFACE
ThisrisrtherSolutionsrManualrforrthertextbookrFundamentalsrofrModernrManufacturing:rMateria
ls,rProcesses,randrSystemsr(SecondrEdition).rItrcontainsrtheranswersrtortherReviewrQuestionsrandr
MultiplerChoicerQuizzesratrtherendrofrtherChaptersr2rthroughr44,rasrwellrasrtherProblemsratrtherendrofrC
haptersr3,r4,r6,r10,r11,r13,r16,r18,r19,r20,r21,r22,r23,r24,r25,r26,r29,r30,
31,r33,r34,r35,r38,r40,r42,randr43.rThererarerapproximatelyr740rreviewrquestions,r500rquizrquestions,randr
500rproblemsr(nearlyrallrofrthemrquantitative)rinrthertext.
Irhaverpersonallyransweredrallrofrtherquestionsrandrsolvedrallrofrtherquizzesrandrproblemsrandrhaverpersona
llyrrecordedrthersolutionsrinrthisrbooklet.rManyrofrtherproblemsrhaverbeenrtestedrinrclass,rthusrgivingrmera
nropportunityrtorcomparermyrownranswersrwithrthoserdevelopedrbyrtherstudents.rDespitermyrbestreffortsrt
oravoidrerrorsrinrthisrsolutionsrmanual,rIramrsurerthatrerrorsrarerpresent.rIrwouldrappreciaterhearingrfromrth
oserofryourwhordiscoverrthesererrors,rsorthatrIrcanrmakerthernecessaryrcorrectionsrinrsubsequentreditionsro
frtherSolutionsrManual.rSimilarly,rIrwouldrappreciateranyrsuggestionsrfromrusersrofrthertextritselfrthatrmig
htrhelprtormakeranyrsubsequentreditionsrmoreraccurate,rmorerrelevant,randreasierrtoruse.rMyraddressris:
Dr.rMikellrP.rGroover
DepartmentrofrIndustrialrandrManufacturingrSystemsrEngineeringrLe
highrUniversity
200rWestrPackerrAvenuer
Bethlehem,rPAr18015
Officertelephonernumberr610-758-
4030.rFaxrmachinernumberr610-758-
4886.
E-
mailraddresses:reitherrMikell.
orrmpg0
@Lehigh.edu
IrhoperyourfindrthertextrandrthisrSolutionsrManualrtorberhelpfulrteachingraidsrinryourrparticularrmanuf
acturingrcourse.
MikellrP.rGroover
2
,TABLE OF CONTENTS:
r r
Chapter ChapterrTitle* Page
1. Introductionr(Norquestionsrorrproblems)
2. TherNaturerofrMaterials 4
3. MechanicalrPropertiesrofrMaterialsr(P) 7
4. PhysicalrPropertiesrofrMaterialsr(P) 18
5. Dimensions,rTolerances,randrSurfaces 21
6. Metalsr (P) 24
7. Ceramics 29
8. Polymers 32
9. CompositerMaterials 36
10. FundamentalsrofrCastingr(P) 39
11. Metalr Castingr Processesr(P) 49
12. Glassworking 57
13. Shapingr Processesr forr Plasticsr(P) 60
14. RubberrProcessingrTechnology 70
15. ShapingrProcessesrforrPolymerrMatrixrComposites 73
16. PowderrMetallurgyr(P) 76
17. ProcessingrofrCeramicsrandrCermets 84
18. FundamentalsrofrMetalrFormingr(P) 87
19. Bulkr Deformationr Processesr(P) 92
20. SheetrMetalworkingr(P) 112
21. TheoryrofrMetalrMachiningr(P) 122
22. MachiningrOperationsrandrMachinerToolsr(P) 134
23. CuttingrToolrTechnologyr(P) 142
24. EconomicrandrProductrDesignrConsiderationsrinrMachiningr(P) 153
25. GrindingrandrOtherrAbrasiverProcessesr(P) 166
26. NontraditionalrMachiningrandrThermalrCuttingrProcessesr(P) 173
27. HeatrTreatmentrofrMetals 180
28. CleaningrandrSurfacerTreatments 182
29. CoatingrandrDepositionrProcessesr(P) 184
30. FundamentalsrofrWeldingr(P) 190
31. Weldingr Processesr(P) 197
32. Brazing,rSoldering,randrAdhesiverBonding 207
33. MechanicalrAssemblyr(P) 211
34. RapidrPrototypingr(P) 218
35. ProcessingrofrIntegratedrCircuitsr(P) 222
36. ElectronicsrAssemblyrandrPackaging 230
37. MicrofabricationrTechnologies 233
38. NumericalrControlrandrIndustrialrRoboticsr(P) 235
39. GrouprTechnologyrandrFlexiblerManufacturingrSystems 244
40. ProductionrLinesr(P) 246
41. ManufacturingrEngineering 253
42. ProductionrPlanningrandrControlr(P) 256
43. QualityrControlr(P) 263
44. MeasurementrandrInspection 271
*(P)rindicatesrchaptersrwithrproblemrsets.
3
, 2 THE NATURE OF MATERIALS
ReviewrQuestions
r r r
2.1 TherelementsrlistedrinrtherPeriodicrTablercanrberdividedrintorthreercategories.rWhatrarerthesercate
goriesrandrgiveranrexamplerofreach?
Answer.rTherthreertypesrofrelementsrarermetalsr(e.g.,raluminum),rnonmetalsr(e.g.,roxygen),randrsemimet
alsr(e.g.,rsilicon).
2.2 Whichrelementsrarerthernoblermetals?
Answer.rThernoblermetalsrarercopper,rsilver,randrgold.
2.3 Whatrisrtherdifferencerbetweenrprimaryrandrsecondaryrbondingrinrtherstructurerofrmaterials?
Answer.rPrimaryrbondingrisrstrongrbondingrbetweenratomsrinrarmaterial,rforrexamplertorformrarmolecule;
rwhilersecondaryrbondingrisrnotrasrstrongrandrisrassociatedrwithrattractionrbetweenrmoleculesrinrthermate
rial.
2.4 Describerhowrionicrbondingrworks?
Answer.rInrionicrbonding,ratomsrofronerelementrgiveruprtheirrouterrelectron(s)rtortheratomsrofranothe
rrelementrtorformrcompleterouterrshells.
2.5 Whatrisrtherdifferencerbetweenrcrystallinerandrnoncrystallinerstructuresrinrmaterials?
Answer.rTheratomsrinrarcrystallinerstructurerarerlocatedratrregularrandrrepeatingrlatticerpositionsrinrthre
erdimensions;rthus,rthercrystalrstructurerpossessesrarlong-
rangerorderrwhichrallowsrarhighrpackingrdensity.r Theratomsrinrarnoncrystallinerstructurerarerrandomlyr
positionedrinrthermaterial,rnotrpossessingranyrrepeating,rregularrpattern.
2.6 Whatrarersomercommonrpointrdefectsrinrarcrystalrlatticerstructure?
Answer.rSomerofrthercommonrpointrdefectsrare:r(1)rvacancyr -
rarmissingratomrinrtherlatticerstructure;r(2)rion-pairrvacancyr(Schottkyrdefect)r-
rarmissingrpairrofrionsrofroppositerchargerinrarcompound;r(3)rinterstitialcyr-
rardistortionrinrtherlatticercausedrbyranrextraratomrpresent;randr(4)rFrenkelrdefectr-
ranrionrisrremovedrfromrarregularrpositionrinrtherlatticerandrinsertedrintoranrinterstitialrpositionrnotrn
ormallyroccupiedrbyrsuchranrion.
2.7 Definertherdifferencerbetweenrelasticrandrplasticrdeformationrinrtermsrofrthereffectronrthercrystalrlatti
cerstructure.
Answer.rElasticrdeformationrinvolvesrartemporaryrdistortionrofrtherlatticerstructurerthatrisrproportiona
lrtortherappliedrstress.rPlasticrdeformationrinvolvesrarstressrofrsufficientrmagnitudertorcauserarpermane
ntrshiftrinrtherrelativerpositionsrofradjacentratomsrinrtherlattice.rPlasticrdeformationrgenerallyrinvolvesrt
hermechanismrofrslipr-rrelativermovementrofratomsronroppositersidesrofrarplanerinrtherlattice.
2.8 Howrdorgrainrboundariesrcontributertortherstrainrhardeningrphenomenonrinrmetals?
Answer.rGrainrboundariesrblockrthercontinuedrmovementrofrdislocationsrinrthermetalrduringrstrain
ing.r Asrmorerdislocationsrbecomerblocked,rthermetalrbecomesrmorerdifficultrtordeform;rinreffectritrb
ecomesrstronger.
2.9 Identifyrsomermaterialsrthatrhaverarcrystallinerstructure.
4
FUNDAMENTALSOF r r
MODERN MANUFAC r
TURING:
MATERIALS, PROCESSES, AND SYSTEMS
r r r
Second Edition r
MIKELL P. GROOVER
r r
Professor of Industrial and Manufacturing Systems EngineeringLehig
r r r r r r r
h University
r
John Wiley & Sons, Inc., New York
r r r r r r
1
,PREFACE
ThisrisrtherSolutionsrManualrforrthertextbookrFundamentalsrofrModernrManufacturing:rMateria
ls,rProcesses,randrSystemsr(SecondrEdition).rItrcontainsrtheranswersrtortherReviewrQuestionsrandr
MultiplerChoicerQuizzesratrtherendrofrtherChaptersr2rthroughr44,rasrwellrasrtherProblemsratrtherendrofrC
haptersr3,r4,r6,r10,r11,r13,r16,r18,r19,r20,r21,r22,r23,r24,r25,r26,r29,r30,
31,r33,r34,r35,r38,r40,r42,randr43.rThererarerapproximatelyr740rreviewrquestions,r500rquizrquestions,randr
500rproblemsr(nearlyrallrofrthemrquantitative)rinrthertext.
Irhaverpersonallyransweredrallrofrtherquestionsrandrsolvedrallrofrtherquizzesrandrproblemsrandrhaverpersona
llyrrecordedrthersolutionsrinrthisrbooklet.rManyrofrtherproblemsrhaverbeenrtestedrinrclass,rthusrgivingrmera
nropportunityrtorcomparermyrownranswersrwithrthoserdevelopedrbyrtherstudents.rDespitermyrbestreffortsrt
oravoidrerrorsrinrthisrsolutionsrmanual,rIramrsurerthatrerrorsrarerpresent.rIrwouldrappreciaterhearingrfromrth
oserofryourwhordiscoverrthesererrors,rsorthatrIrcanrmakerthernecessaryrcorrectionsrinrsubsequentreditionsro
frtherSolutionsrManual.rSimilarly,rIrwouldrappreciateranyrsuggestionsrfromrusersrofrthertextritselfrthatrmig
htrhelprtormakeranyrsubsequentreditionsrmoreraccurate,rmorerrelevant,randreasierrtoruse.rMyraddressris:
Dr.rMikellrP.rGroover
DepartmentrofrIndustrialrandrManufacturingrSystemsrEngineeringrLe
highrUniversity
200rWestrPackerrAvenuer
Bethlehem,rPAr18015
Officertelephonernumberr610-758-
4030.rFaxrmachinernumberr610-758-
4886.
E-
mailraddresses:reitherrMikell.
orrmpg0
@Lehigh.edu
IrhoperyourfindrthertextrandrthisrSolutionsrManualrtorberhelpfulrteachingraidsrinryourrparticularrmanuf
acturingrcourse.
MikellrP.rGroover
2
,TABLE OF CONTENTS:
r r
Chapter ChapterrTitle* Page
1. Introductionr(Norquestionsrorrproblems)
2. TherNaturerofrMaterials 4
3. MechanicalrPropertiesrofrMaterialsr(P) 7
4. PhysicalrPropertiesrofrMaterialsr(P) 18
5. Dimensions,rTolerances,randrSurfaces 21
6. Metalsr (P) 24
7. Ceramics 29
8. Polymers 32
9. CompositerMaterials 36
10. FundamentalsrofrCastingr(P) 39
11. Metalr Castingr Processesr(P) 49
12. Glassworking 57
13. Shapingr Processesr forr Plasticsr(P) 60
14. RubberrProcessingrTechnology 70
15. ShapingrProcessesrforrPolymerrMatrixrComposites 73
16. PowderrMetallurgyr(P) 76
17. ProcessingrofrCeramicsrandrCermets 84
18. FundamentalsrofrMetalrFormingr(P) 87
19. Bulkr Deformationr Processesr(P) 92
20. SheetrMetalworkingr(P) 112
21. TheoryrofrMetalrMachiningr(P) 122
22. MachiningrOperationsrandrMachinerToolsr(P) 134
23. CuttingrToolrTechnologyr(P) 142
24. EconomicrandrProductrDesignrConsiderationsrinrMachiningr(P) 153
25. GrindingrandrOtherrAbrasiverProcessesr(P) 166
26. NontraditionalrMachiningrandrThermalrCuttingrProcessesr(P) 173
27. HeatrTreatmentrofrMetals 180
28. CleaningrandrSurfacerTreatments 182
29. CoatingrandrDepositionrProcessesr(P) 184
30. FundamentalsrofrWeldingr(P) 190
31. Weldingr Processesr(P) 197
32. Brazing,rSoldering,randrAdhesiverBonding 207
33. MechanicalrAssemblyr(P) 211
34. RapidrPrototypingr(P) 218
35. ProcessingrofrIntegratedrCircuitsr(P) 222
36. ElectronicsrAssemblyrandrPackaging 230
37. MicrofabricationrTechnologies 233
38. NumericalrControlrandrIndustrialrRoboticsr(P) 235
39. GrouprTechnologyrandrFlexiblerManufacturingrSystems 244
40. ProductionrLinesr(P) 246
41. ManufacturingrEngineering 253
42. ProductionrPlanningrandrControlr(P) 256
43. QualityrControlr(P) 263
44. MeasurementrandrInspection 271
*(P)rindicatesrchaptersrwithrproblemrsets.
3
, 2 THE NATURE OF MATERIALS
ReviewrQuestions
r r r
2.1 TherelementsrlistedrinrtherPeriodicrTablercanrberdividedrintorthreercategories.rWhatrarerthesercate
goriesrandrgiveranrexamplerofreach?
Answer.rTherthreertypesrofrelementsrarermetalsr(e.g.,raluminum),rnonmetalsr(e.g.,roxygen),randrsemimet
alsr(e.g.,rsilicon).
2.2 Whichrelementsrarerthernoblermetals?
Answer.rThernoblermetalsrarercopper,rsilver,randrgold.
2.3 Whatrisrtherdifferencerbetweenrprimaryrandrsecondaryrbondingrinrtherstructurerofrmaterials?
Answer.rPrimaryrbondingrisrstrongrbondingrbetweenratomsrinrarmaterial,rforrexamplertorformrarmolecule;
rwhilersecondaryrbondingrisrnotrasrstrongrandrisrassociatedrwithrattractionrbetweenrmoleculesrinrthermate
rial.
2.4 Describerhowrionicrbondingrworks?
Answer.rInrionicrbonding,ratomsrofronerelementrgiveruprtheirrouterrelectron(s)rtortheratomsrofranothe
rrelementrtorformrcompleterouterrshells.
2.5 Whatrisrtherdifferencerbetweenrcrystallinerandrnoncrystallinerstructuresrinrmaterials?
Answer.rTheratomsrinrarcrystallinerstructurerarerlocatedratrregularrandrrepeatingrlatticerpositionsrinrthre
erdimensions;rthus,rthercrystalrstructurerpossessesrarlong-
rangerorderrwhichrallowsrarhighrpackingrdensity.r Theratomsrinrarnoncrystallinerstructurerarerrandomlyr
positionedrinrthermaterial,rnotrpossessingranyrrepeating,rregularrpattern.
2.6 Whatrarersomercommonrpointrdefectsrinrarcrystalrlatticerstructure?
Answer.rSomerofrthercommonrpointrdefectsrare:r(1)rvacancyr -
rarmissingratomrinrtherlatticerstructure;r(2)rion-pairrvacancyr(Schottkyrdefect)r-
rarmissingrpairrofrionsrofroppositerchargerinrarcompound;r(3)rinterstitialcyr-
rardistortionrinrtherlatticercausedrbyranrextraratomrpresent;randr(4)rFrenkelrdefectr-
ranrionrisrremovedrfromrarregularrpositionrinrtherlatticerandrinsertedrintoranrinterstitialrpositionrnotrn
ormallyroccupiedrbyrsuchranrion.
2.7 Definertherdifferencerbetweenrelasticrandrplasticrdeformationrinrtermsrofrthereffectronrthercrystalrlatti
cerstructure.
Answer.rElasticrdeformationrinvolvesrartemporaryrdistortionrofrtherlatticerstructurerthatrisrproportiona
lrtortherappliedrstress.rPlasticrdeformationrinvolvesrarstressrofrsufficientrmagnitudertorcauserarpermane
ntrshiftrinrtherrelativerpositionsrofradjacentratomsrinrtherlattice.rPlasticrdeformationrgenerallyrinvolvesrt
hermechanismrofrslipr-rrelativermovementrofratomsronroppositersidesrofrarplanerinrtherlattice.
2.8 Howrdorgrainrboundariesrcontributertortherstrainrhardeningrphenomenonrinrmetals?
Answer.rGrainrboundariesrblockrthercontinuedrmovementrofrdislocationsrinrthermetalrduringrstrain
ing.r Asrmorerdislocationsrbecomerblocked,rthermetalrbecomesrmorerdifficultrtordeform;rinreffectritrb
ecomesrstronger.
2.9 Identifyrsomermaterialsrthatrhaverarcrystallinerstructure.
4
