SolutionswManualwtowAccompany
MATERIALS AND PROCESS IN MANUFACTURING
w w w w
Ninth Edition w
E. Paul DeGarmo
w w w
J T. Black
w w
Ronald A. Kohserw w
SolutionswManualwby
Barney E. Klamecki
w w
Copyrightw©w2003wJohnwWileyw&wSons,wInc
, Contents
Preface Page 1
Chapterw1 IntroductionwtowMaterialswandwProcesseswinwManufacturing Page 3
Chapterw2 PropertieswofwMaterials Page 10
Chapterw3 NaturewofwMetalswandwAlloys Page 20
Chapterw4 EquilibriumwPhasewDiagramswandwthewIron-CarbonwSystem Page 26
Chapterw5 HeatwTreatment Page 34
Chapterw6 FerrouswMetalswandwAlloys Page 42
Chapterw7 NonferrouswMetalswandwAlloys Page 49
Chapterw8 NonmetallicwMaterials:wPlastics,wElastomers
,wCeramics,wandwComposites Page 54
Chapterw9 MaterialwSelection Page 63
Chapterw10wMeasurementwandwInspection Page 72
Chapterw11wNondestructivewInspectionwandwTesting Page 82
Chapterw12wProcesswCapabilitywandwQualitywControl Page 92
Chapterw13wFundamentalswofwCasting Page 107
Chapterw14wExpendable-MoldwCastingwProcesses Page 116
Chapterw15wMultiple-Use-MoldwCastingwProcesses Page 124
Chapterw16wPowderwMetallurgy Page 131
Chapterw17wFundamentalswofwMetalwForming Page 140
Chapterw18wHot-Working Page 150
Chapterw19wCold-WorkingwProcesses Page 159
Chapterw20wFabricationwofwPlastics,wCeramics,wandwComposites Page 173
Chapterw21wFundamentalswofwMachiningw/wOrthogonalwMachining Page 182
Chapterw22wCuttingwToolswforwMachining Page 194
Chapterw23wTurningwandwBoringwandwRelatedwprocesses Page 208
Chapterw24wDrillingwandwRelatedwHolewMakingwProcesses Page 217
Chapterw25wMilling Page 223
Chapterw26wShaping,wPlaning,wBroaching,wSawing,wandwFiling Page 229
Chapterw27wAbrasivewMachiningwProcesses Page 237
Chapterw28wNontraditionalwMachining Page 242
Chapterw29wWorkholdingwDevices Page 247
Chapterw30wThreadwandwGearwManufacturing Page 252
Chapterw31wSurfacewTreatments,wFinishing,wandwIntegrity Page 259
Chapterw32wManufacturingwAutomation Page 267
Chapterw33wRapidwPrototypingwandwFreeformwFabrication Page 283
Chapterw34wMicroelectronicwManufacturingwandwElectronicwAssembly Page 291
Chapterw35wFundamentalswofwJoining Page 303
Chapterw36wGaswFlamewProcesses Page 308
Chapterw37wArcwprocesses Page 310
Chapterw38wResistancewWeldingwandwOtherwWeldingwProcesses Page 316
Chapterw39wBrazingwandwSoldering Page 323
Chapterw40wAdhesivewBondingwandwMechanicalwFastening Page 327
Chapterw41wManufacturingwandwProductionwSystems Page 333
Chapterw42wSystemwandwCellwDesign Page 341
Chapterw43wImplementationwofwLeanwManufacturingwSystemswandwCells Page 349
, Preface
Thiswversionwofwthewtextbookwcontainswsignificantwnewwcontentwand,wsowthen,wdoeswthewSo
lutionwManual.wThesewnoteswarewprovidedwtowexplainwsomewaspectswofwthewnewwcontent.
Thewauthorswofwthewtextbookwpreparedwthewnewwcontentwforwthewbook,wincludingwallwneww
questionswandwproblems.wIwpreparedwonlywthewanswerswtowthewnewwquestionswandwsolutions
wforwthewnewwproblems.
Manywofwthewquestionswarewbroad,wopen-
endedwandwraisewreal,wpracticalwconcerns.wThewanswerswthatwIwhavewpreparedwarewintended
wtowdirectlywaddress wthewimportantwconcepts wraisedwandwprovidewsomewofwthewthought wproc
esswleadingwtowthewanswers.wWherewexamplewapplicationswofwthewconceptswarewprovidedwth
esewarewintendedwtowbewstartingwpointswforwconsiderationwandwdiscussion,wnotwfinal,wdefinit
eworwuniquewanswers.
Somewinternetwwebwsiteswarewsuggestedwaswexamplewsiteswcontainingwusefulwinformation.w
Thesewarewonlywsuggestionswaswtypicalwstartingwpointswforwmorewin-
depthwinvestigationwofwthewquestionswraised.wIwamwalwayswhesitantwtowreferwtowinternetwwe
bwsiteswsincewoftenwthewupdatingwofwthem,wandwsometimeswtheirwcontinuedwexistence,wiswpr
oblematic.wPerhapswthewbestwwaywtowviewwthewinclusionwofwawwebwsitewinwthewSolutionwMa
nualwiswaswanwindicationwofwquestionswthatwarewmorewopen-
endedwandwmaywrequirewmorewmaterialwthanwiswinwthewtextwforwpreparingwanswers.
Forwthewnewwquantitativewproblemswandwsomewofwthewproblemswfromwpreviousweditionswofw
thewtextwIwhavewusedwspreadsheetswtowproducewsolutions.wThewintentwiswtowprovidewthewopp
ortunitywforwuserswofwthewtextwtowcustomizewthesewproblems.wProblemwvariableswandwvaria
blewvalueswcanwbewchangeswwithwlittleweffort.wThewdifficultywiswthatwtowprovidewthiswcapabi
litywspecificwsoftwarewmustwbewusedwsincewwritingwcodewthatwcanwbewusedwonwmostwcompu
terswiswnotwwarranted.wMicrosoftwExcelw97wwaswused.wInwanywcase,wthewsolutionswarewalsowp
rovidedwinwfixedwform.
Somewquestionwanswerswwerewputwinwthewformwofwtableswsowthatwitwiswpossiblewtowslightlyw
manipulatewthewquestions.wForwexample,wvariouswtablewcellswcanwbewclearedwandwfill-in-
the-
blankwquestionswformulated.wMicrosoftwWordw97wwaswusedwforwthewSolutionwManualwtext
w
.
BarneywE.wKlameck
iwMarch,w2003
1
, 2
MATERIALS AND PROCESS IN MANUFACTURING
w w w w
Ninth Edition w
E. Paul DeGarmo
w w w
J T. Black
w w
Ronald A. Kohserw w
SolutionswManualwby
Barney E. Klamecki
w w
Copyrightw©w2003wJohnwWileyw&wSons,wInc
, Contents
Preface Page 1
Chapterw1 IntroductionwtowMaterialswandwProcesseswinwManufacturing Page 3
Chapterw2 PropertieswofwMaterials Page 10
Chapterw3 NaturewofwMetalswandwAlloys Page 20
Chapterw4 EquilibriumwPhasewDiagramswandwthewIron-CarbonwSystem Page 26
Chapterw5 HeatwTreatment Page 34
Chapterw6 FerrouswMetalswandwAlloys Page 42
Chapterw7 NonferrouswMetalswandwAlloys Page 49
Chapterw8 NonmetallicwMaterials:wPlastics,wElastomers
,wCeramics,wandwComposites Page 54
Chapterw9 MaterialwSelection Page 63
Chapterw10wMeasurementwandwInspection Page 72
Chapterw11wNondestructivewInspectionwandwTesting Page 82
Chapterw12wProcesswCapabilitywandwQualitywControl Page 92
Chapterw13wFundamentalswofwCasting Page 107
Chapterw14wExpendable-MoldwCastingwProcesses Page 116
Chapterw15wMultiple-Use-MoldwCastingwProcesses Page 124
Chapterw16wPowderwMetallurgy Page 131
Chapterw17wFundamentalswofwMetalwForming Page 140
Chapterw18wHot-Working Page 150
Chapterw19wCold-WorkingwProcesses Page 159
Chapterw20wFabricationwofwPlastics,wCeramics,wandwComposites Page 173
Chapterw21wFundamentalswofwMachiningw/wOrthogonalwMachining Page 182
Chapterw22wCuttingwToolswforwMachining Page 194
Chapterw23wTurningwandwBoringwandwRelatedwprocesses Page 208
Chapterw24wDrillingwandwRelatedwHolewMakingwProcesses Page 217
Chapterw25wMilling Page 223
Chapterw26wShaping,wPlaning,wBroaching,wSawing,wandwFiling Page 229
Chapterw27wAbrasivewMachiningwProcesses Page 237
Chapterw28wNontraditionalwMachining Page 242
Chapterw29wWorkholdingwDevices Page 247
Chapterw30wThreadwandwGearwManufacturing Page 252
Chapterw31wSurfacewTreatments,wFinishing,wandwIntegrity Page 259
Chapterw32wManufacturingwAutomation Page 267
Chapterw33wRapidwPrototypingwandwFreeformwFabrication Page 283
Chapterw34wMicroelectronicwManufacturingwandwElectronicwAssembly Page 291
Chapterw35wFundamentalswofwJoining Page 303
Chapterw36wGaswFlamewProcesses Page 308
Chapterw37wArcwprocesses Page 310
Chapterw38wResistancewWeldingwandwOtherwWeldingwProcesses Page 316
Chapterw39wBrazingwandwSoldering Page 323
Chapterw40wAdhesivewBondingwandwMechanicalwFastening Page 327
Chapterw41wManufacturingwandwProductionwSystems Page 333
Chapterw42wSystemwandwCellwDesign Page 341
Chapterw43wImplementationwofwLeanwManufacturingwSystemswandwCells Page 349
, Preface
Thiswversionwofwthewtextbookwcontainswsignificantwnewwcontentwand,wsowthen,wdoeswthewSo
lutionwManual.wThesewnoteswarewprovidedwtowexplainwsomewaspectswofwthewnewwcontent.
Thewauthorswofwthewtextbookwpreparedwthewnewwcontentwforwthewbook,wincludingwallwneww
questionswandwproblems.wIwpreparedwonlywthewanswerswtowthewnewwquestionswandwsolutions
wforwthewnewwproblems.
Manywofwthewquestionswarewbroad,wopen-
endedwandwraisewreal,wpracticalwconcerns.wThewanswerswthatwIwhavewpreparedwarewintended
wtowdirectlywaddress wthewimportantwconcepts wraisedwandwprovidewsomewofwthewthought wproc
esswleadingwtowthewanswers.wWherewexamplewapplicationswofwthewconceptswarewprovidedwth
esewarewintendedwtowbewstartingwpointswforwconsiderationwandwdiscussion,wnotwfinal,wdefinit
eworwuniquewanswers.
Somewinternetwwebwsiteswarewsuggestedwaswexamplewsiteswcontainingwusefulwinformation.w
Thesewarewonlywsuggestionswaswtypicalwstartingwpointswforwmorewin-
depthwinvestigationwofwthewquestionswraised.wIwamwalwayswhesitantwtowreferwtowinternetwwe
bwsiteswsincewoftenwthewupdatingwofwthem,wandwsometimeswtheirwcontinuedwexistence,wiswpr
oblematic.wPerhapswthewbestwwaywtowviewwthewinclusionwofwawwebwsitewinwthewSolutionwMa
nualwiswaswanwindicationwofwquestionswthatwarewmorewopen-
endedwandwmaywrequirewmorewmaterialwthanwiswinwthewtextwforwpreparingwanswers.
Forwthewnewwquantitativewproblemswandwsomewofwthewproblemswfromwpreviousweditionswofw
thewtextwIwhavewusedwspreadsheetswtowproducewsolutions.wThewintentwiswtowprovidewthewopp
ortunitywforwuserswofwthewtextwtowcustomizewthesewproblems.wProblemwvariableswandwvaria
blewvalueswcanwbewchangeswwithwlittleweffort.wThewdifficultywiswthatwtowprovidewthiswcapabi
litywspecificwsoftwarewmustwbewusedwsincewwritingwcodewthatwcanwbewusedwonwmostwcompu
terswiswnotwwarranted.wMicrosoftwExcelw97wwaswused.wInwanywcase,wthewsolutionswarewalsowp
rovidedwinwfixedwform.
Somewquestionwanswerswwerewputwinwthewformwofwtableswsowthatwitwiswpossiblewtowslightlyw
manipulatewthewquestions.wForwexample,wvariouswtablewcellswcanwbewclearedwandwfill-in-
the-
blankwquestionswformulated.wMicrosoftwWordw97wwaswusedwforwthewSolutionwManualwtext
w
.
BarneywE.wKlameck
iwMarch,w2003
1
, 2
