SolutionsManual # #
for DeGarmos Ma
# #
terials and Proces # #
ses in Manufactur
# #
ing, 13e Black, Ro
# # #
nald Kohser (All C
# # #
hapters)
, CHAPTER#1
Introduction#to#DeGarmo’s#Materials#and#Processes#in#Manufacturing
Review#Questions
1. The#availability#and#cost#of#manufactured#products#are#an#important#part#of#our#cost#o
f#living#and#the#real#wealth#of#the#nation.#Thus,#reducing#the#cost#of#producer#and#consum
er#goods#improves#the#productivity#while#holding#down#inflation,#thereby#improving#the#
general#standard#of#living.
2. This#is#true#if#you#consider#that#everyone#who#uses#the#output#from#a#process,#inclu
ding#all#the#intermediate#steps,#is#a#customer.# The#operator#of#the#next#process#is#the#user#a
nd#customer#of#the#proceeding#process.#In#fact,#some#companies#identify#two#customers,#
the#external#customer#who#buys#the#finished#product#and#the#internal#customer,#who#buil
ds#the#product#one#-#i.e.,#the#people#who#work#in#the#manufacturing#system.
3. Job#shop#-
#an#injection#mold#manufacturing#shop,#the#shop#at#a#large#university#that#produces#researc
h#equipment#and#apparatus.# Job#shops#are#capable#of#producing#products#with#great#variety
,#typically#employing#highly#skilled#workers.
Flow#shop#–
#automobile#assembly.#Flow#shops#are#usually#laid#out#so#that#specific#products#pass#t
hrough#a#series#of#operations#with#no#backflow.# The#product#range#is#limited,#product
ion#volume#is#large#and#labor#skill#is#lower#than#in#job#shops.
Project#shop#–#diesel-
electric#locomotive#production#facility.# The#end#product#is#very#large#and#so#many#ma
chines,#tools#and#people#come#to#the#product#to#produce#it#at#a#relatively#fixed#location.
The#Subway#sandwich#shop#would#be#a#flow#shop.
4. In#the#context#of#manufacturing,#a#manufacturing#system#is#a#collection#of#men,#ma
chine#tools,#and#material-
moving#systems,#collected#together#to#accomplish#specific#manufacturing#or#fabrication#
sequences,#resulting#in#components#or#end#products.# The#manufacturing#system#is#back
ed#up#by#and#supported#by#the#production#system,#which#includes#functions#like#control#o
f#quality,#inventory,#production,#and#manpower,#as#well#as#scheduling,#planning#and#the#l
ike.#Within#the#manufacturing#system,#there#will#be#machine#tools,#which#can#perform#j
obs#or
5. No.#The#cutting#tool#is#the#implement#that#does#the#cutting.#It#contains#the#cutting#ed
ge#and#is#used#in#the#machine#tool.##The#machine#tool#drives#the#cutting#tool#through#the#
work#material.
6. The#basic#manufacturing#processes#are:#casting#or#molding,#forming,#(heat)#t
reating,#metal#removal,#finishing,#joining#(welding),#assembly,#and#inspection.
1
,7. Casting#could#be#used,#provided#the#material#can#be#melted#and#poured#in#the#approp
riate#process.#By#casting,#the#desired#shaped#in#final#or#near-
final#form,#could#be#obtained.#This#greatly#reduces#the#necessity#for#machining#the#hard-
to-
machine#metal.#Less#machining#is#needed#when#the#raw#material#shape#is#close#to#the#fin
ished#part#size#and#shape#(called#near#net#shape#casting).#The#part#could#also#be#made#in#s
impler#segments#and#assembled#or#joined.
8. The#wax#pattern#is#melted#and#removed#as#a#liquid.#Any#remaining#wax#is#then#v
aporized#when#the#mold#is#heated#in#preparation#for#the#pour.
9. A#relief-
image#is#the#cavity#in#the#die#that#the#work#material#is#deformed#into#when#the#die#is#pres
sed#into#the#workpiece.# Material#on#the#workpiece#moving#into#the#cavity,#“concave,”#of#t
he#die#results#in#the#raised,#“convex,”#part#of#the#medal#surface.
10. Trains#stop#at#the#station#to#load#and#unload#people#and#materials.#In#an#assembly#line,#p
roducts#stop#at#stations#to#take#on#materials#or#have#operations#performed#on#them.
11. False.#Storage#is#very#expensive#because#time#costs#the#company#money.#It#is#ex
pensive#to#keep#track#of#stored#materials,#to#put#them#into#storage,#to#get#them#back#fro
m#storage,#to#damage#them#as#a#result#of#excessive#handling,#and#so#on.#More#import
antly,#storage#usually#adds#no#value#-#very#few#items#appreciate#on#the#shelf.
12. For#the#simple,#conventional#paper#clip,#forming#processes#are#first#used#to#make#and#c
oat#wire,#which#is#then#cut#to#length#and#formed#in#three#bending#operations.
13. Tools#are#used#to#hold,#cut,#shape,#or#form#the#unfinished#product.#Common#hand#to
ols#include#the#saw,#hammer,#screwdriver,#chisel,#punch,#sandpaper,#drill,#clamp,#file,#tor
ch,#and#grindstone.#Basically,#machines#are#mechanized#versions#of#such#hand#tools#and#
are#called#cutting#tools.#Some#examples#of#tools#for#cutting#are#drill#bits,#reamers,#single
-
point#turning#tools,#milling#cutters,#saw#blades,#broaches,#and#grinding#wheels.#Noncutti
ng#tools#for#forming#include#extrusion#dies,#punches,#and#molds.#Tools#also#include#wor
kholders,#jigs,#and#fixtures.#These#tools#and#cutting#tools#are#generally#referred#to#as#the#
tooling,#which#usually#must#be#considered#(purchased)#separate#from#machine#tools.
14. Inefficient#is#a#relative#term#here.#If#we#can#eliminate#machining,#we#can#save#the#time
#and#the#money. #Machining#processes#are#generally#those#which#give#the#part#its#final#size
,#shape,#and#surface#finish#and#add#value#to#the#part.#Because#they#do#not#produce#the#shap
e#and#size#in#bulk,#but#rather#by#localized#action#they#may#not#be#as#efficient#as#forming#an
d#casting#processes.#Cutting#tool#and#workholding#tooling#expenses#may#also#be#reduced,#
since#the#same#tool#can#work#on#many#different#products.
15. Figure#1-1#and#figure#1-
16#both#show#life#cycle#progressions.# For#an#audiocassette#tape,#it#went#to#a#commodity#
product,#and#is#now#in#decline#as#CD’s#are#taking#over.#We#will#know#that#it#is#in#severe
#decline#when#the#new#autos#no#longer#offer#cassette#players.
2
, 16. The#cost#to#manufacture#a#typical#manufactured#product#is#20%#-
#30%#of#the#selling#price.#For#the#mass#produced#product#at#the#lower#end#of#this#range#t
he#manufacturing#cost#is#$0.20.#These#20#cents#includes#material#and#processing#costs.#
Processing#includes#assembly#in#addition#to#producing#the#components.# Since#the#blade#c
ost#involves#forming#the#edge#in#a#material#it#is#probably#the#highest#cost#part#of#the#raz
or.
So,#with#20#cents#to#cover#materials,#processing#and#assembly,#and#the#blade#the#most#e
xpensive#individual#part#an#estimate#of#2-
3#cents#is#reasonable#for#the#production#of#the#high#precision#(in#terms#of#edge)#blade.
The#same#kind#of#reasoning#can#be#used#with#manufacturing#cost#being#40%#of#s
elling#cost#as#suggested#in#Problems#1#and#2.
17. Packaging#is#used#to#protect#the#product#from#the#environment,#to#protect#the#product#d
uring#shipping#and#to#hold#fixed#numbers#of#products#for#sale.
18. Assembly#of#a#binder#type#paper#clip#involves#putting#the#formed#wire#handles#in#to#t
he#spring#steel#binder#part#of#the#clip.#Assembly#of#bicycle#wheels#involves#putting#spok
es#into#the#wheel#and#hub.
If#the#ingredients#of#the#club#sandwich#are#all#in#their#finished#state#then#they#can#be#ass
embled.#If#processing#is#necessary#as#in#slicing#as#turkey,#the#entire#process#is#more#than#just#
assembly.
19. The#physical#elements#of#a#manufacturing#system#are#the#machine#tools,#the#tooling#li
ke#workholding#devices,#material#handling#equipment,#inspection#equipment#and#people#
who#actually#produce#the#products.#Manufacturing#systems#are#characterized#by#measura
ble#parameters#(throughput#time,#cycle#time,#defect#rates,#production#rates,#number#of#dir
ect#laborers,#annual#production#volumes,#etc.).#Machine#tools#are#characterized#by#the#siz
e#of#the#workpiece#that#can#be#processed#or#the#spindle#speeds#they#can#be#run#at.#Tools#li
ke#dies#for#sheet#metal#forming#are#characterized#by#their#size#and#weight.#Inspection#dev
ices#have#measurement#resolution#limits.#Measurable#parameters#extend#past#machine#sp
ecifications#to#higher#level#(involving#more#than#one#aspect#of#part#production)#descriptio
ns#of#the#process#such#as#production#rates.#The#manufacturing#system#is#more#than#the#ph
ysical#elements.#Support#and#control#systems,#along#with#the#physical#elements,#are#comb
ined#in#the#manufacturing#system.
20. The#manufacturing#engineer#is#responsible#for#selecting#or#designing#and#overseeing#o
peration#of#the#manufacturing#processes.#In#the#sense#of#immediate#contact#with#processes
#the#manufacturing#engineer#is#often#the#center#of#“making#the#product”.#However,#the#dec
isions#made#by#part#and#product#designers#and#materials#engineers#have#large#influences#o
n#the#kind#of#processes#that#can#be#used#to#make#the#part.#How#the#part#can#be#made#is#cons
trained#by#part#design#and#materials#used.#So,#all#individuals#who#make#decisions#that#dete
rmine#manufacturing#process#choice#should#be#involved#in#figuring#out#how#to#make#the#p
art.
21. In#Figure#1-
8,#the#lines#connecting#the#processes#represent#possible#paths#as#material#moves#through#t
he#shop#–#from#machine-to-machine#or#operation-to-operation.
3
for DeGarmos Ma
# #
terials and Proces # #
ses in Manufactur
# #
ing, 13e Black, Ro
# # #
nald Kohser (All C
# # #
hapters)
, CHAPTER#1
Introduction#to#DeGarmo’s#Materials#and#Processes#in#Manufacturing
Review#Questions
1. The#availability#and#cost#of#manufactured#products#are#an#important#part#of#our#cost#o
f#living#and#the#real#wealth#of#the#nation.#Thus,#reducing#the#cost#of#producer#and#consum
er#goods#improves#the#productivity#while#holding#down#inflation,#thereby#improving#the#
general#standard#of#living.
2. This#is#true#if#you#consider#that#everyone#who#uses#the#output#from#a#process,#inclu
ding#all#the#intermediate#steps,#is#a#customer.# The#operator#of#the#next#process#is#the#user#a
nd#customer#of#the#proceeding#process.#In#fact,#some#companies#identify#two#customers,#
the#external#customer#who#buys#the#finished#product#and#the#internal#customer,#who#buil
ds#the#product#one#-#i.e.,#the#people#who#work#in#the#manufacturing#system.
3. Job#shop#-
#an#injection#mold#manufacturing#shop,#the#shop#at#a#large#university#that#produces#researc
h#equipment#and#apparatus.# Job#shops#are#capable#of#producing#products#with#great#variety
,#typically#employing#highly#skilled#workers.
Flow#shop#–
#automobile#assembly.#Flow#shops#are#usually#laid#out#so#that#specific#products#pass#t
hrough#a#series#of#operations#with#no#backflow.# The#product#range#is#limited,#product
ion#volume#is#large#and#labor#skill#is#lower#than#in#job#shops.
Project#shop#–#diesel-
electric#locomotive#production#facility.# The#end#product#is#very#large#and#so#many#ma
chines,#tools#and#people#come#to#the#product#to#produce#it#at#a#relatively#fixed#location.
The#Subway#sandwich#shop#would#be#a#flow#shop.
4. In#the#context#of#manufacturing,#a#manufacturing#system#is#a#collection#of#men,#ma
chine#tools,#and#material-
moving#systems,#collected#together#to#accomplish#specific#manufacturing#or#fabrication#
sequences,#resulting#in#components#or#end#products.# The#manufacturing#system#is#back
ed#up#by#and#supported#by#the#production#system,#which#includes#functions#like#control#o
f#quality,#inventory,#production,#and#manpower,#as#well#as#scheduling,#planning#and#the#l
ike.#Within#the#manufacturing#system,#there#will#be#machine#tools,#which#can#perform#j
obs#or
5. No.#The#cutting#tool#is#the#implement#that#does#the#cutting.#It#contains#the#cutting#ed
ge#and#is#used#in#the#machine#tool.##The#machine#tool#drives#the#cutting#tool#through#the#
work#material.
6. The#basic#manufacturing#processes#are:#casting#or#molding,#forming,#(heat)#t
reating,#metal#removal,#finishing,#joining#(welding),#assembly,#and#inspection.
1
,7. Casting#could#be#used,#provided#the#material#can#be#melted#and#poured#in#the#approp
riate#process.#By#casting,#the#desired#shaped#in#final#or#near-
final#form,#could#be#obtained.#This#greatly#reduces#the#necessity#for#machining#the#hard-
to-
machine#metal.#Less#machining#is#needed#when#the#raw#material#shape#is#close#to#the#fin
ished#part#size#and#shape#(called#near#net#shape#casting).#The#part#could#also#be#made#in#s
impler#segments#and#assembled#or#joined.
8. The#wax#pattern#is#melted#and#removed#as#a#liquid.#Any#remaining#wax#is#then#v
aporized#when#the#mold#is#heated#in#preparation#for#the#pour.
9. A#relief-
image#is#the#cavity#in#the#die#that#the#work#material#is#deformed#into#when#the#die#is#pres
sed#into#the#workpiece.# Material#on#the#workpiece#moving#into#the#cavity,#“concave,”#of#t
he#die#results#in#the#raised,#“convex,”#part#of#the#medal#surface.
10. Trains#stop#at#the#station#to#load#and#unload#people#and#materials.#In#an#assembly#line,#p
roducts#stop#at#stations#to#take#on#materials#or#have#operations#performed#on#them.
11. False.#Storage#is#very#expensive#because#time#costs#the#company#money.#It#is#ex
pensive#to#keep#track#of#stored#materials,#to#put#them#into#storage,#to#get#them#back#fro
m#storage,#to#damage#them#as#a#result#of#excessive#handling,#and#so#on.#More#import
antly,#storage#usually#adds#no#value#-#very#few#items#appreciate#on#the#shelf.
12. For#the#simple,#conventional#paper#clip,#forming#processes#are#first#used#to#make#and#c
oat#wire,#which#is#then#cut#to#length#and#formed#in#three#bending#operations.
13. Tools#are#used#to#hold,#cut,#shape,#or#form#the#unfinished#product.#Common#hand#to
ols#include#the#saw,#hammer,#screwdriver,#chisel,#punch,#sandpaper,#drill,#clamp,#file,#tor
ch,#and#grindstone.#Basically,#machines#are#mechanized#versions#of#such#hand#tools#and#
are#called#cutting#tools.#Some#examples#of#tools#for#cutting#are#drill#bits,#reamers,#single
-
point#turning#tools,#milling#cutters,#saw#blades,#broaches,#and#grinding#wheels.#Noncutti
ng#tools#for#forming#include#extrusion#dies,#punches,#and#molds.#Tools#also#include#wor
kholders,#jigs,#and#fixtures.#These#tools#and#cutting#tools#are#generally#referred#to#as#the#
tooling,#which#usually#must#be#considered#(purchased)#separate#from#machine#tools.
14. Inefficient#is#a#relative#term#here.#If#we#can#eliminate#machining,#we#can#save#the#time
#and#the#money. #Machining#processes#are#generally#those#which#give#the#part#its#final#size
,#shape,#and#surface#finish#and#add#value#to#the#part.#Because#they#do#not#produce#the#shap
e#and#size#in#bulk,#but#rather#by#localized#action#they#may#not#be#as#efficient#as#forming#an
d#casting#processes.#Cutting#tool#and#workholding#tooling#expenses#may#also#be#reduced,#
since#the#same#tool#can#work#on#many#different#products.
15. Figure#1-1#and#figure#1-
16#both#show#life#cycle#progressions.# For#an#audiocassette#tape,#it#went#to#a#commodity#
product,#and#is#now#in#decline#as#CD’s#are#taking#over.#We#will#know#that#it#is#in#severe
#decline#when#the#new#autos#no#longer#offer#cassette#players.
2
, 16. The#cost#to#manufacture#a#typical#manufactured#product#is#20%#-
#30%#of#the#selling#price.#For#the#mass#produced#product#at#the#lower#end#of#this#range#t
he#manufacturing#cost#is#$0.20.#These#20#cents#includes#material#and#processing#costs.#
Processing#includes#assembly#in#addition#to#producing#the#components.# Since#the#blade#c
ost#involves#forming#the#edge#in#a#material#it#is#probably#the#highest#cost#part#of#the#raz
or.
So,#with#20#cents#to#cover#materials,#processing#and#assembly,#and#the#blade#the#most#e
xpensive#individual#part#an#estimate#of#2-
3#cents#is#reasonable#for#the#production#of#the#high#precision#(in#terms#of#edge)#blade.
The#same#kind#of#reasoning#can#be#used#with#manufacturing#cost#being#40%#of#s
elling#cost#as#suggested#in#Problems#1#and#2.
17. Packaging#is#used#to#protect#the#product#from#the#environment,#to#protect#the#product#d
uring#shipping#and#to#hold#fixed#numbers#of#products#for#sale.
18. Assembly#of#a#binder#type#paper#clip#involves#putting#the#formed#wire#handles#in#to#t
he#spring#steel#binder#part#of#the#clip.#Assembly#of#bicycle#wheels#involves#putting#spok
es#into#the#wheel#and#hub.
If#the#ingredients#of#the#club#sandwich#are#all#in#their#finished#state#then#they#can#be#ass
embled.#If#processing#is#necessary#as#in#slicing#as#turkey,#the#entire#process#is#more#than#just#
assembly.
19. The#physical#elements#of#a#manufacturing#system#are#the#machine#tools,#the#tooling#li
ke#workholding#devices,#material#handling#equipment,#inspection#equipment#and#people#
who#actually#produce#the#products.#Manufacturing#systems#are#characterized#by#measura
ble#parameters#(throughput#time,#cycle#time,#defect#rates,#production#rates,#number#of#dir
ect#laborers,#annual#production#volumes,#etc.).#Machine#tools#are#characterized#by#the#siz
e#of#the#workpiece#that#can#be#processed#or#the#spindle#speeds#they#can#be#run#at.#Tools#li
ke#dies#for#sheet#metal#forming#are#characterized#by#their#size#and#weight.#Inspection#dev
ices#have#measurement#resolution#limits.#Measurable#parameters#extend#past#machine#sp
ecifications#to#higher#level#(involving#more#than#one#aspect#of#part#production)#descriptio
ns#of#the#process#such#as#production#rates.#The#manufacturing#system#is#more#than#the#ph
ysical#elements.#Support#and#control#systems,#along#with#the#physical#elements,#are#comb
ined#in#the#manufacturing#system.
20. The#manufacturing#engineer#is#responsible#for#selecting#or#designing#and#overseeing#o
peration#of#the#manufacturing#processes.#In#the#sense#of#immediate#contact#with#processes
#the#manufacturing#engineer#is#often#the#center#of#“making#the#product”.#However,#the#dec
isions#made#by#part#and#product#designers#and#materials#engineers#have#large#influences#o
n#the#kind#of#processes#that#can#be#used#to#make#the#part.#How#the#part#can#be#made#is#cons
trained#by#part#design#and#materials#used.#So,#all#individuals#who#make#decisions#that#dete
rmine#manufacturing#process#choice#should#be#involved#in#figuring#out#how#to#make#the#p
art.
21. In#Figure#1-
8,#the#lines#connecting#the#processes#represent#possible#paths#as#material#moves#through#t
he#shop#–#from#machine-to-machine#or#operation-to-operation.
3
