Solutions Manual
for DeGarmos
Materials and
Processes in
Manufacturing,
13e Black,
Ronald Kohser
(All Chapters)
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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.
1
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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 value to the part. Because they do not
produce the shape and size in bulk, but rather by localized action they 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.
2
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, 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 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 engineers have
large influences on the kind of processes that can be used to make the part. How the part
can be made is constrained by part design and materials used. So, all individuals who
make decisions that determine manufacturing process choice should be involved in
figuring out how to make the part.
21. In Figure 1-8, the lines connecting the processes represent possible paths as material
moves through the shop – from machine-to-machine or operation-to-operation.
3
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for DeGarmos
Materials and
Processes in
Manufacturing,
13e Black,
Ronald Kohser
(All Chapters)
Downloaded by: tutorsection | Want to earn $1.236
Distribution of this document is illegal extra per year?
, 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.
1
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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 value to the part. Because they do not
produce the shape and size in bulk, but rather by localized action they 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.
2
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, 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 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 engineers have
large influences on the kind of processes that can be used to make the part. How the part
can be made is constrained by part design and materials used. So, all individuals who
make decisions that determine manufacturing process choice should be involved in
figuring out how to make the part.
21. In Figure 1-8, the lines connecting the processes represent possible paths as material
moves through the shop – from machine-to-machine or operation-to-operation.
3
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