SOLUTION MANUAL - DeGarmo's Materials
and Processes in Manufacturing 14th Edition by
Ronald A. Kohser, J. T. Black
ALL CHAPTERS 1-43| VERIFIED STUDY
GUIDE FOR THE STUDY
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Page 1 of 464
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, 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 of living and the real
wealth of the nation. Thus, reducing the cost of producer and consumer 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, including all the intermediate
steps, is a customer. The operator of the next process is the user and 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 builds 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 research
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 through a
series of operations with no backflow. The product range is limited, production 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
machines, 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, machine tools, and material-
moving systems, collected together to accomplish specific manufacturing or fabrication sequences, resulting in
components or end products. The manufacturing system is backed up by and supported by the production
system, which includes functions like control of quality, inventory, production, and manpower, as well as
scheduling, planning and the like. Within the manufacturing system, there will be machine tools, which can
perform jobs or
5. No. The cutting tool is the implement that does the cutting. It contains the cutting edge 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) treating, metal removal,
finishing, joining (welding), assembly, and inspection.
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, 7. Casting could be used, provided the material can be melted and poured in the appropriate 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
finished part size and shape (called near net shape casting). The part could also be made in simpler segments
and assembled or joined.
8. The wax pattern is melted and removed as a liquid. Any remaining wax is then vaporized 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 pressed into the
workpiece. Material on the workpiece moving into the cavity, ―concave,‖ of the 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, products 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 expensive to keep track of
stored materials, to put them into storage, to get them back from storage, to damage them as a result of
excessive handling, and so on. More importantly, 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 coat 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 tools include the saw,
hammer, screwdriver, chisel, punch, sandpaper, drill, clamp, file, torch, 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.
Noncutting tools for forming include extrusion dies, punches, and molds. Tools also include workholders, 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
TB
value to the part. Because they do not produce the shape and size in bulk, but rather by localized action they
Ac
Page 3 of 464
er
, may not be as efficient as forming and 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.
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 the 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 cost involves forming the edge in a material it is probably the highest cost part of the razor. So, with
20 cents to cover materials, processing and assembly, and the blade the most expensive 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 selling cost as suggested in
Problems 1 and 2.
17. Packaging is used to protect the product from the environment, to protect the product during 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 the spring steel binder
part of the clip. Assembly of bicycle wheels involves putting spokes into the wheel and hub.
If the ingredients of the club sandwich are all in their finished state then they can be assembled. 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 like workholding
devices, material handling equipment, inspection equipment and people who actually produce the products.
Manufacturing systems are characterized by measurable parameters (throughput time, cycle time, defect rates,
production rates, number of direct laborers, annual production volumes, etc.). Machine tools are characterized
by the size of the workpiece that can be processed or the spindle speeds they can be run at. Tools like dies for
sheet metal forming are characterized by their size and weight. Inspection devices have measurement
resolution limits. Measurable parameters extend past machine specifications to higher level (involving more
than one aspect of part production) descriptions of the process such as production rates. The manufacturing
system is more than the physical elements. Support and control systems, along with the physical elements, are
combined in the manufacturing system.
20. The manufacturing engineer is responsible for selecting or designing and overseeing operation of the
TB
manufacturing processes. In the sense of immediate contact with processes the manufacturing engineer is often
the center of ―making the product‖. However, the decisions made by part and product designers and materials
Ac
Page 4 of 464
er
and Processes in Manufacturing 14th Edition by
Ronald A. Kohser, J. T. Black
ALL CHAPTERS 1-43| VERIFIED STUDY
GUIDE FOR THE STUDY
TB
Ac
Page 1 of 464
er
, 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 of living and the real
wealth of the nation. Thus, reducing the cost of producer and consumer 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, including all the intermediate
steps, is a customer. The operator of the next process is the user and 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 builds 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 research
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 through a
series of operations with no backflow. The product range is limited, production 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
machines, 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, machine tools, and material-
moving systems, collected together to accomplish specific manufacturing or fabrication sequences, resulting in
components or end products. The manufacturing system is backed up by and supported by the production
system, which includes functions like control of quality, inventory, production, and manpower, as well as
scheduling, planning and the like. Within the manufacturing system, there will be machine tools, which can
perform jobs or
5. No. The cutting tool is the implement that does the cutting. It contains the cutting edge 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) treating, metal removal,
finishing, joining (welding), assembly, and inspection.
TB
Ac
Page 2 of 464
er
, 7. Casting could be used, provided the material can be melted and poured in the appropriate 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
finished part size and shape (called near net shape casting). The part could also be made in simpler segments
and assembled or joined.
8. The wax pattern is melted and removed as a liquid. Any remaining wax is then vaporized 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 pressed into the
workpiece. Material on the workpiece moving into the cavity, ―concave,‖ of the 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, products 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 expensive to keep track of
stored materials, to put them into storage, to get them back from storage, to damage them as a result of
excessive handling, and so on. More importantly, 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 coat 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 tools include the saw,
hammer, screwdriver, chisel, punch, sandpaper, drill, clamp, file, torch, 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.
Noncutting tools for forming include extrusion dies, punches, and molds. Tools also include workholders, 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
TB
value to the part. Because they do not produce the shape and size in bulk, but rather by localized action they
Ac
Page 3 of 464
er
, may not be as efficient as forming and 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.
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 the 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 cost involves forming the edge in a material it is probably the highest cost part of the razor. So, with
20 cents to cover materials, processing and assembly, and the blade the most expensive 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 selling cost as suggested in
Problems 1 and 2.
17. Packaging is used to protect the product from the environment, to protect the product during 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 the spring steel binder
part of the clip. Assembly of bicycle wheels involves putting spokes into the wheel and hub.
If the ingredients of the club sandwich are all in their finished state then they can be assembled. 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 like workholding
devices, material handling equipment, inspection equipment and people who actually produce the products.
Manufacturing systems are characterized by measurable parameters (throughput time, cycle time, defect rates,
production rates, number of direct laborers, annual production volumes, etc.). Machine tools are characterized
by the size of the workpiece that can be processed or the spindle speeds they can be run at. Tools like dies for
sheet metal forming are characterized by their size and weight. Inspection devices have measurement
resolution limits. Measurable parameters extend past machine specifications to higher level (involving more
than one aspect of part production) descriptions of the process such as production rates. The manufacturing
system is more than the physical elements. Support and control systems, along with the physical elements, are
combined in the manufacturing system.
20. The manufacturing engineer is responsible for selecting or designing and overseeing operation of the
TB
manufacturing processes. In the sense of immediate contact with processes the manufacturing engineer is often
the center of ―making the product‖. However, the decisions made by part and product designers and materials
Ac
Page 4 of 464
er
