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fundamentals of modern manufacturing materials processes and systems 4th edition solutions manual

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fundamentals of modern manufacturing materials processes and systems 4th edition solutions manual

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SOLUTION MANUAL

,SolutionsxforxFundamentalsxofxModernxManufacturing,x4/ex(publishedxbyxWiley)xxMPGrooverx2010x
06-19-09



1 INTRODUCTION
ReviewxQuestions
1.1 Whatxarexthexdifferencesxbetweenxprimary,xsecondary,xandxtertiaryxindustries?xGivexanxexamplexofx
eachxcategory.
Answer.xAxprimaryxindustryxisxonexthatxcultivatesxandxexploitsxnaturalxresources,xsuchxasxagricultur
exorxmining.xAxsecondaryxindustryxtakesxthexoutputsxofxprimaryxindustriesxandxconvertsxthemxtoxcons
umerxandxcapitalxgoods.xExamplesxofxsecondaryxindustriesxarextextilesxandxelectronics.xAxtertiaryxind
ustryxisxinxthexservicexsectorxofxthexeconomy.xExamplesxofxtertiaryxindustriesxarexbankingxandxeducat
ion.
1.2 Whatxisxaxcapitalxgood?xProvidexanxexample.
Answer.xCapitalxgoodsxarexthosexpurchasedxbyxcompaniesxtoxproducexgoodsxorxprovidexservices.xExam
plesxofxcapitalxgoodsxarexaircraftxandxconstructionxequipment.
1.3 Howxarexproductxvarietyxandxproductionxquantityxrelatedxwhenxcomparingxtypicalxfactories?
Answer.xGenerallyxproductionxquantityxisxinverselyxrelatedxtoxproductxvariety.xAxfactoryxthatx
producesxaxlargexvarietyxofxproductsxwillxproducexaxsmallerxquantityxofxeach.xAxcompanyxthatx
producesxaxsinglexproductxwillxproducexaxlargexquantity.
1.4 Definexmanufacturingxcapability.
Answer.xManufacturingxcapabilityxrefersxtoxthextechnicalxandxphysicalxlimitationsxofxaxmanufactur
ingxfirmxandxeachxofxitsxplants.xThreexcategoriesxofxcapabilityxmentionedxinxthextextxare
(1)xtechnologicalxprocessingxcapability,x(2)xphysicalxsizexandxweight,xandx(3)xproductionxcapacity.
1.5 Namexthexthreexbasicxcategoriesxofxmaterials.
Answer.xThexthreexbasicxcategoriesxofxengineeringxmaterialsxarex(1)xmetals,x(2)xceramics,xandx(3)xpoly
mers.xAxfourthxcategory,xcomposites,xisxaxnon-
homogeneousxmixturexofxthexotherxtypesxandxthereforexisxnotxaxbasicxcategory.
1.6 Howxdoesxaxshapingxprocessxdifferxfromxaxsurfacexprocessingxoperation?
Answer.xAxshapingxprocessxchangesxthexgeometryxofxthexworkxmaterialx(machiningxorxforging).xAxsu
rfacexprocessingxoperationxdoesxnotxalterxthexgeometry,xbutxinsteadxaltersxsurfacexofxthexworkx(painti
ngxorxplating).
1.7 Whatxarextwoxsubclassesxofxassemblyxprocesses?xProvidexanxexamplexprocessxforxeachxsubclass.
Answer.xThextwoxsubclassesxofxassemblyxprocessesxarex(1)xpermanentxjoiningxandx(2)xmechanicalxfaste
ning.xExamplesxofxpermanentxjoiningxincludexweldingxorxadhesivexbonding.xExamplesxofxmechanicalxf
asteningxincludexthreadedxfasteners,xsuchxasxnutsxandxbolts,xandxrivets.
1.8 Definexbatchxproductionxandxdescribexwhyxitxisxoftenxusedxforxmedium-
quantityxproductionxproducts.
Answer.xBatchxproductionxisxwherexgroups,xlots,xorxbatchesxorxmaterialsxorxpartsxarexprocessedxtoget
herxthroughxthexmanufacturingxoperations.xAllxunitsxinxthexbatchxarexprocessedxatxaxgivenxstationxbef
orexthexgroupxproceedsxtoxthexnextxstation.xInxaxmediumxorxlowxquantityxproductionxsituation,xthexsa
mexmachinesxarexusedxtoxproducexmanyxtypesxofxproducts.xWheneverxaxmachinexswitchesxfromxonex
productxtoxanother,xaxchangeoverxoccurs.xThexchangeoverxrequiresxthexmachinexsetupxtoxbextornxdow
nxandxsetxupxforxthexnewxproduct.xBatchxproductionxallowsxthexchangeoverxtime

Excerptsxfromxthisxworkxmayxbexreproducedxbyxinstructorsxforxdistributionxonxaxnot-for-
profitxbasisxforxtestingxorxinstructionalxpurposesxonlyxtox studentsxenrolledxinxcoursesxforxwhichxthextextbookxhasxbeenxadopted.x Anyxotherxrep
roductionxorxtranslationxofxthisxworkxbeyondxthatxpermittedx byxSectionsx107xorx108xofxthex1976xUnitedxStatesxCopyrightxActxwithoutxthexpermi
ssionxofxthexcopyrightxownerxisxunlawful.
1

,SolutionsxforxFundamentalsxofxModernxManufacturing,x4/ex(publishedxbyxWiley)xxMPGrooverx2010x
06-19-09
toxbexdistributedxacrossxaxlargerxnumberxofxpartsxandxhencexreducexthexaveragexoperationxtimexperxpar
t.
1.9 Whatxisxthexdifferencexbetweenxaxprocessxlayoutxandxaxproductxlayoutxinxaxproductionxfacility?
Answer.xAxprocessxlayoutxisxonexwherexthexmachineryxinxaxplantxisxarrangedxbasedxonxthextypexofxpr
ocessxitxperforms.xToxproducexaxproductxitxmustxvisitxthexdepartmentsxinxthexorderxofxthexoperationsxt
hatxmustxbexperformed.xThisxoftenxincludesxlargextravelxdistancesxwithinxthexplant.xAxprocessxlayoutx
isxoftenxusedxwhenxthexproductxvarietyxisxlargexthexoperationxsequencesxofxproductsxarexdissimilar.x A
xproductxlayoutxisxonexwherexthexmachineryxisxarrangedxbasedxonxthexgeneralxflowxofxthexproductsxtha

txwillxbexproduced.xTravelxdistancexisxreducedxbecausexproductsxwillxgenerallyxflowxtoxthexnextxmac
hinexinxthexsequence.xAxproductxlayoutxworksxwellxwhenxallxproductsxtendxtoxfollowxthexsamexseque
ncexofxproduction.
1.10 Namextwoxdepartmentsxthatxarextypicallyxclassifiedxasxmanufacturingxsupportxdepartments.
Answer.xAxcommonxorganizationalxstructurexincludesxthexfollowingxthreexmanufacturingxsupportx
departments:x(1)xmanufacturingxengineering,x(2)xproductionxplanningxandxcontrol,xandx(3)xqualityx
control.
MultiplexChoicexQuiz
Therexarex18xcorrectxanswersxinxthexfollowingxmultiplexchoicexquestionsx(somexquestionsxhavexmultiplexans
wersxthatxarexcorrect).xToxattainxaxperfectxscorexonxthexquiz,xallxcorrectxanswersxmustxbexgiven.xEachxcorrectx
answerxisxworthx1xpoint.xEachxomittedxanswerxorxwrongxanswerxreducesxthexscorexbyx1xpoint,xandxeachxadditi
onalxanswerxbeyondxthexcorrectxnumberxofxanswersxreducesxthexscorexbyx1xpoint.xPercentagexscorexonxthexquiz
xisxbasedxonxthextotalxnumberxofxcorrectxanswers.


1.1 Whichxofxthexfollowingxindustriesxarexclassifiedxasxsecondaryxindustriesx(threexcorrectxanswers):x(a)x
beveragesx(b)xfinancialxservices,x(c)xfishing,x(d)xmining,x(e)xpowerxutilities,x(f)xpublishing,xandx(g)xtr
ansportation?
Answer.x(a),x(e),xandx(f).
1.2 Miningxisxclassifiedxinxwhichxonexofxthexfollowingxindustryxcategories:x(a)xagriculturalxindustry,x(b)x
manufacturingxindustry,x(c)xprimaryxindustry,x(d)xsecondaryxindustry,x(e)xservicexindustry,xorx(f)xtert
iaryxindustry?
Answer.x(c).
1.3 InventionsxofxthexIndustrialxRevolutionxincludexwhichxonexofxthexfollowing:x(a)xautomobile,x(b)x
cannon,x(c)xprintingxpress,x(d)xsteamxengine,xorx(e)xsword?
Answer.x(d).
1.4 Ferrousxmetalsxincludexwhichxofxthexfollowingx(twoxcorrectxanswers):x(a)xaluminum,x(b)xcastxiron,
(c)xcopper,x(d)xgold,xandx(e)xsteel?
Answer.x(c)xandx(e).
1.5 Whichxonexofxthexfollowingxengineeringxmaterialsxisxdefinedxasxaxcompoundxcontainingxmetallicx
andxnonmetallicxelements:x(a)xceramic,x(b)xcomposite,x(c)xmetal,xorx(d)xpolymer?
Answer.x(a).
1.6 Whichxofxthexfollowingxprocessesxstartxwithxaxmaterialxthatxisxinxaxfluidxorxsemifluidxstatexandxsol
idifiesxthexmaterialxinxaxcavityx(twoxbestxanswers):x(a)xcasting,x(b)xforging,x(c)xmachining,x(d)xmo
lding,x(e)xpressing,xandx(f)xturning?
Answer.x(a)xandx(d).

Excerptsxfromxthisxworkxmayxbexreproducedxbyxinstructorsxforxdistributionxonxaxnot-for-
profitxbasisxforxtestingxorxinstructionalxpurposesxonlyxtox studentsxenrolledxinxcoursesxforxwhichxthextextbookxhasxbeenxadopted.x Anyxotherxrep
roductionxorxtranslationxofxthisxworkxbeyondxthatxpermittedx byxSectionsx107xorx108xofxthex1976xUnitedxStatesxCopyrightxActxwithoutxthexpermi
ssionxofxthexcopyrightxownerxisxunlawful.
2

, SolutionsxforxFundamentalsxofxModernxManufacturing,x4/ex(publishedxbyxWiley)xxMPGrooverx2010x
06-19-09
1.7 Particulatexprocessingxofxmetalsxandxceramicsxinvolvesxwhichxofxthexfollowingxstepsx(twoxbestxans
wers):x(a)xadhesivexbonding,x(b)xdeformation,x(c)xforging,x(d)xmaterialxremoval,x(e)xmelting,x(f)xpre
ssing,xandx(g)xsintering?
Answer.x(f)xandx(g).
1.8 Deformationxprocessesxincludexwhichxofxthexfollowingx(twoxcorrectxanswers):x(a)xcasting,x(b)x
drilling,x(c)xextrusion,x(d)xforging,x(e)xmilling,x(f)xpainting,xandx(g)xsintering?
Answer.x(c)xandx(d).
1.9 Whichxonexofxthexfollowingxisxaxmachinexusedxtoxperformxextrusion:x(a)xforgexhammer,x(b)xmillingx
machine,x(c)xrollingxmill,x(d)xpress,x(e)xtorch?
Answer.x(d).
1.10 High-
volumexproductionxofxassembledxproductsxisxmostxcloselyxassociatedxwithxwhichxonexofxthexfollo
wingxlayoutxtypes:x(a)xcellularxlayout,x(b)xfixedxpositionxlayout,x(c)xprocessxlayout,xorx(d)xproductx
layout?
Answer.x(d).
1.11 Axproductionxplanningxandxcontrolxdepartmentxaccomplishesxwhichxofxthexfollowingxfunctionsxinxitsx
rolexofxprovidingxmanufacturingxsupportx(twoxbestxanswers):x(a)xdesignsxandxordersxmachinextools,
(b)xdevelopsxcorporatexstrategicxplans,x(c)xordersxmaterialsxandxpurchasedxparts,x(d)xperformsxqu
alityxinspections,xandx(e)xschedulesxthexorderxofxproductsxonxaxmachine?
Answer.x(c)xandx(e).




Excerptsxfromxthisxworkxmayxbexreproducedxbyxinstructorsxforxdistributionxonxaxnot-for-
profitxbasisxforxtestingxorxinstructionalxpurposesxonlyxtox studentsxenrolledxinxcoursesxforxwhichxthextextbookxhasxbeenxadopted.x Anyxotherxrep
roductionxorxtranslationxofxthisxworkxbeyondxthatxpermittedx byxSectionsx107xorx108xofxthex1976xUnitedxStatesxCopyrightxActxwithoutxthexpermi
ssionxofxthexcopyrightxownerxisxunlawful.
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