1
,PREFACE
This is the Solutions Manual for the textbook Fundamentals of Modern Manufacturing: Materials,
zl zl zl zl zl zl zl zl zl zl zl zl
Processes, and Systems (Second Edition). It contains the answers to the Review Questions and Multi
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
ple Choice Quizzes at the end of the Chapters 2 through 44, as well as the Problems at the end of Chapters
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3, 4, 6, 10, 11, 13, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 29, 30,
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
31, 33, 34, 35, 38, 40, 42, and 43. There are approximately 740 review questions, 500 quiz questions, and
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500 problems (nearly all of them quantitative) in the text.
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I have personally answered all of the questions and solved all of the quizzes and problems and have person
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ally recorded the solutions in this booklet. Many of the problems have been tested in class, thus giving me
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an opportunity to compare my own answers with those developed by the students. Despite my best effort
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s to avoid errors in this solutions manual, I am sure that errors are present. I would appreciate hearing fro
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
m those of you who discover these errors, so that I can make the necessary corrections in subsequent edi
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tions of the Solutions Manual. Similarly, I would appreciate any suggestions from users of the text itself t
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hat might help to make any subsequent editions more accurate, more relevant, and easier to use. My addre
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ss is: zl
Dr. Mikell P. Groover zl zl zl
Department of Industrial and Manufacturing Systems Engineering Le zl zl zl zl zl zl zl
high University zl
200 West Packer Avenue Bethlehe
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m, PA 18015 zl zl
Office telephone number 610-758- zl zl zl
4030. Fax machine number 610-758- zl zl zl zl
4886.
E-
mail addresses: either Mikell. zl zl zl
or zl
u
I hope you find the text and this Solutions Manual to be helpful teaching aids in your particular manufa
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cturing course. zl
Mikell P. Groover zl zl
2
,TABLE OF CONTENTS:
zl zl
Chapter Chapter Title* zl Page
1. Introduction (No questions or problems) zl zl zl zl
2. The Nature of Materials
zl zl zl 4
3. Mechanical Properties of Materials (P) zl zl zl zl 7
4. Physical Properties of Materials (P) zl zl zl zl 18
5. Dimensions, Tolerances, and Surfaces zl zl zl 21
6. Metals (P) zl 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials zl 36
10. Fundamentals of Casting (P) zl zl zl 39
11. Metal Casting Processes (P)
zl zl zl 49
12. Glassworking 57
13. Shaping Processes for Plastics (P) zl zl zl zl 60
14. Rubber Processing Technologyzl zl 70
15. Shaping Processes for Polymer Matrix Composites
zl zl zl zl zl 73
16. Powder Metallurgy (P) zl zl 76
17. Processing of Ceramics and Cermets zl zl zl zl 84
18. Fundamentals of Metal Forming (P) zl zl zl zl 87
19. Bulk Deformation Processes (P)
zl zl zl 92
20. Sheet Metalworking (P)
zl zl 112
21. Theory of Metal Machining (P)
zl zl zl zl 122
22. Machining Operations and Machine Tools (P) zl zl zl zl zl 134
23. Cutting Tool Technology (P) zl zl zl 142
24. Economic and Product Design Considerations in Machining (P)
zl zl zl zl zl zl zl 153
25. Grinding and Other Abrasive Processes (P) zl zl zl zl zl 166
26. Nontraditional Machining and Thermal Cutting Processes (P) zl zl zl zl zl zl 173
27. Heat Treatment of Metals
zl zl zl 180
28. Cleaning and Surface Treatments zl zl zl 182
29. Coating and Deposition Processes (P)
zl zl zl zl 184
30. Fundamentals of Welding (P) zl zl zl 190
31. Welding Processes (P) zl zl 197
32. Brazing, Soldering, and Adhesive Bonding
zl zl zl zl 207
33. Mechanical Assembly (P) zl zl 211
34. Rapid Prototyping (P)
zl zl 218
35. Processing of Integrated Circuits (P) zl zl zl zl 222
36. Electronics Assembly and Packaging zl zl zl 230
37. Microfabrication Technologies zl 233
38. Numerical Control and Industrial Robotics (P) zl zl zl zl zl 235
39. Group Technology and Flexible Manufacturing Systems
zl zl zl zl zl 244
40. Production Lines (P) zl zl 246
41. Manufacturing Engineering zl 253
42. Production Planning and Control (P) zl zl zl zl 256
43. Quality Control (P) zl zl 263
44. Measurement and Inspection zl zl 271
*(P) indicates chapters with problem sets.
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3
, 2 THE NATURE OF MATERIALS zl zl zl
Review Questions
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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? zl zl zl zl zl zl
Answer. The three types of elements are metals (e.g., aluminum), nonmetals (e.g., oxygen), and semimet
zl zl zl zl zl zl zl zl zl zl zl zl zl zl
als (e.g., silicon).
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2.2 Which elements are the noble metals? zl zl zl zl zl
Answer. The noble metals are copper, silver, and gold. zl zl zl zl zl zl zl zl
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 t
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he material.
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2.4 Describe how ionic bonding works? zl zl zl zl
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. zl zl zl zl zl
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 th
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ree 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 randomly
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positioned in the material, not possessing any repeating, regular pattern. zl zl zl zl zl zl zl zl zl
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 - zl zl zl zl zl zl zl zl zl zl
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 nor
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mally occupied by such an ion. zl zl zl zl zl
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. zl
Answer. Elastic deformation involves a temporary distortion of the lattice structure that is proportion
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al to the applied stress. Plastic deformation involves a stress of sufficient magnitude to cause a perm
zl zl zl zl z l zl zl zl zl zl zl zl zl zl zl zl
anent shift in the relative positions of adjacent atoms in the lattice. Plastic deformation generally invol
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ves 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. zl
2.9 Identify some materials that have a crystalline structure.zl zl zl zl zl zl zl
4
,PREFACE
This is the Solutions Manual for the textbook Fundamentals of Modern Manufacturing: Materials,
zl zl zl zl zl zl zl zl zl zl zl zl
Processes, and Systems (Second Edition). It contains the answers to the Review Questions and Multi
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
ple Choice Quizzes at the end of the Chapters 2 through 44, as well as the Problems at the end of Chapters
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3, 4, 6, 10, 11, 13, 16, 18, 19, 20, 21, 22, 23, 24, 25, 26, 29, 30,
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
31, 33, 34, 35, 38, 40, 42, and 43. There are approximately 740 review questions, 500 quiz questions, and
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
500 problems (nearly all of them quantitative) in the text.
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I have personally answered all of the questions and solved all of the quizzes and problems and have person
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ally recorded the solutions in this booklet. Many of the problems have been tested in class, thus giving me
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
an opportunity to compare my own answers with those developed by the students. Despite my best effort
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
s to avoid errors in this solutions manual, I am sure that errors are present. I would appreciate hearing fro
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
m those of you who discover these errors, so that I can make the necessary corrections in subsequent edi
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
tions of the Solutions Manual. Similarly, I would appreciate any suggestions from users of the text itself t
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
hat might help to make any subsequent editions more accurate, more relevant, and easier to use. My addre
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
ss is: zl
Dr. Mikell P. Groover zl zl zl
Department of Industrial and Manufacturing Systems Engineering Le zl zl zl zl zl zl zl
high University zl
200 West Packer Avenue Bethlehe
zl zl zl zl
m, PA 18015 zl zl
Office telephone number 610-758- zl zl zl
4030. Fax machine number 610-758- zl zl zl zl
4886.
E-
mail addresses: either Mikell. zl zl zl
or zl
u
I hope you find the text and this Solutions Manual to be helpful teaching aids in your particular manufa
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
cturing course. zl
Mikell P. Groover zl zl
2
,TABLE OF CONTENTS:
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Chapter Chapter Title* zl Page
1. Introduction (No questions or problems) zl zl zl zl
2. The Nature of Materials
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3. Mechanical Properties of Materials (P) zl zl zl zl 7
4. Physical Properties of Materials (P) zl zl zl zl 18
5. Dimensions, Tolerances, and Surfaces zl zl zl 21
6. Metals (P) zl 24
7. Ceramics 29
8. Polymers 32
9. Composite Materials zl 36
10. Fundamentals of Casting (P) zl zl zl 39
11. Metal Casting Processes (P)
zl zl zl 49
12. Glassworking 57
13. Shaping Processes for Plastics (P) zl zl zl zl 60
14. Rubber Processing Technologyzl zl 70
15. Shaping Processes for Polymer Matrix Composites
zl zl zl zl zl 73
16. Powder Metallurgy (P) zl zl 76
17. Processing of Ceramics and Cermets zl zl zl zl 84
18. Fundamentals of Metal Forming (P) zl zl zl zl 87
19. Bulk Deformation Processes (P)
zl zl zl 92
20. Sheet Metalworking (P)
zl zl 112
21. Theory of Metal Machining (P)
zl zl zl zl 122
22. Machining Operations and Machine Tools (P) zl zl zl zl zl 134
23. Cutting Tool Technology (P) zl zl zl 142
24. Economic and Product Design Considerations in Machining (P)
zl zl zl zl zl zl zl 153
25. Grinding and Other Abrasive Processes (P) zl zl zl zl zl 166
26. Nontraditional Machining and Thermal Cutting Processes (P) zl zl zl zl zl zl 173
27. Heat Treatment of Metals
zl zl zl 180
28. Cleaning and Surface Treatments zl zl zl 182
29. Coating and Deposition Processes (P)
zl zl zl zl 184
30. Fundamentals of Welding (P) zl zl zl 190
31. Welding Processes (P) zl zl 197
32. Brazing, Soldering, and Adhesive Bonding
zl zl zl zl 207
33. Mechanical Assembly (P) zl zl 211
34. Rapid Prototyping (P)
zl zl 218
35. Processing of Integrated Circuits (P) zl zl zl zl 222
36. Electronics Assembly and Packaging zl zl zl 230
37. Microfabrication Technologies zl 233
38. Numerical Control and Industrial Robotics (P) zl zl zl zl zl 235
39. Group Technology and Flexible Manufacturing Systems
zl zl zl zl zl 244
40. Production Lines (P) zl zl 246
41. Manufacturing Engineering zl 253
42. Production Planning and Control (P) zl zl zl zl 256
43. Quality Control (P) zl zl 263
44. Measurement and Inspection zl zl 271
*(P) indicates chapters with problem sets.
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3
, 2 THE NATURE OF MATERIALS zl zl zl
Review Questions
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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? zl zl zl zl zl zl
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? zl zl zl zl zl
Answer. The noble metals are copper, silver, and gold. zl zl zl zl zl zl zl zl
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 t
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he material.
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2.4 Describe how ionic bonding works? zl zl zl zl
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. zl zl zl zl zl
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 th
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ree 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 randomly
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positioned in the material, not possessing any repeating, regular pattern. zl zl zl zl zl zl zl zl zl
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 - zl zl zl zl zl zl zl zl zl zl
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 nor
zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
mally occupied by such an ion. zl zl zl zl zl
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. zl
Answer. Elastic deformation involves a temporary distortion of the lattice structure that is proportion
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al to the applied stress. Plastic deformation involves a stress of sufficient magnitude to cause a perm
zl zl zl zl z l zl zl zl zl zl zl zl zl zl zl zl
anent shift in the relative positions of adjacent atoms in the lattice. Plastic deformation generally invol
zl zl zl zl zl zl zl zl zl zl zl z l zl zl zl
ves 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?
zl zl zl zl zl zl zl zl zl zl zl
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
z l zl zl zl zl zl zl zl zl zl zl zl zl zl zl zl
mes stronger. zl
2.9 Identify some materials that have a crystalline structure.zl zl zl zl zl zl zl
4
