SolutionsmManualmtomAccompany
MATERIALS AND PROCESS IN MANUFACTURING
M M M M
Ninth Edition m
E. Paul DeGarmo
m m
J T. Black
m m m
Ronald A. Kohserm m
SolutionsmManualmby
Barney E. Klamecki
m m
Copyright m©m2003mJohnmWileym&mSons,mInc
, Contents
Preface Page 1
Chapterm1 IntroductionmtomMaterialsmand mProcessesminmManufacturing Page 3
Chapterm2 Propertiesmof mMaterials Page 10
Chapterm3 Naturemof mMetalsmand mAlloys Page 20
Chapterm4 EquilibriummPhasemDiagrams mand mthemIron-Carbon mSystem Page 26
Chapterm5 Heat mTreatment Page 34
Chapterm6 FerrousmMetalsmand mAlloys Page 42
Chapterm7 NonferrousmMetalsmand mAlloys Page 49
Chapterm8 NonmetallicmMaterials:mPlastics,mElastomers,mCeramic
s,mand mComposites Page 54
Chapterm9 MaterialmSelection Page 63
Chapterm10mMeasurement mand mInspection Page 72
Chapterm11mNondestructivemInspectionmand mTesting Page 82
Chapterm12mProcessmCapabilitymand mQualitymControl Page 92
Chapterm13mFundamentalsmof mCasting Page 107
Chapterm14mExpendable-Mold mCastingmProcesses Page 116
Chapterm15mMultiple-Use-Mold mCastingmProcesses Page 124
Chapterm16mPowdermMetallurgy Page 131
Chapterm17mFundamentalsmof mMetalmForming Page 140
Chapterm18mHot-Working Page 150
Chapterm19mCold-WorkingmProcesses Page 159
Chapterm20mFabricationmof mPlastics,mCeramics,mand mComposites Page 173
Chapterm21mFundamentalsmof mMachiningm/mOrthogonalmMachining Page 182
Chapterm22mCuttingmToolsmformMachining Page 194
Chapterm23mTurningmand mBoringmand mRelated mprocesses Page 208
Chapterm24mDrillingmand mRelated mHolemMakingmProcesses Page 217
Chapterm25mMilling Page 223
Chapterm26mShaping,mPlaning,mBroaching,mSawing,mand mFiling Page 229
Chapterm27mAbrasivemMachiningmProcesses Page 237
Chapterm28mNontraditionalmMachining Page 242
Chapterm29mWorkholdingmDevices Page 247
Chapterm30mThread mand mGearmManufacturing Page 252
Chapterm31mSurfacemTreatments,mFinishing,mand mIntegrity Page 259
Chapterm32mManufacturingmAutomation Page 267
Chapterm33mRapid mPrototypingmand mFreeformmFabrication Page 283
Chapterm34mMicroelectronicmManufacturingmand mElectronicmAssembly Page 291
Chapterm35mFundamentalsmof mJoining Page 303
Chapterm36mGasmFlamemProcesses Page 308
Chapterm37mArcmprocesses Page 310
Chapterm38mResistancemWeldingmand mOthermWeldingmProcesses Page 316
Chapterm39mBrazingmand mSoldering Page 323
Chapterm40mAdhesivemBondingmand mMechanicalmFastening Page 327
Chapterm41mManufacturingmand mProductionmSystems Page 333
Chapterm42mSystemmand mCellmDesign Page 341
Chapterm43mImplementationmof mLeanmManufacturingmSystemsmand mCells Page 349
, Preface
Thismversionmof mthemtextbookmcontainsmsignificant mnew mcontent mand,msomthen,mdoesmthemSo
lutionmManual.mThesemnotesmaremprovided mtomexplainmsomemaspectsmof mthemnew mcontent.
Themauthorsmof mthemtextbookmprepared mthemnew mcontent mformthembook,mincludingmallmnew m
questionsmand mproblems.mI mprepared monlymthemanswersmtomthemnew mquestionsmand msolution
smformthemnew mproblems.
Manymof mthemquestionsmarembroad,mopen-
ended mand mraisemreal,mpracticalmconcerns.mThemanswersmthat mI mhavemprepared maremintended
mtomdirectlymaddressmthemimportant mconceptsmraised mand mprovidemsomemof mthemthought mpro
cessmleadingmtomthemanswers.mWheremexamplemapplicationsmof mthemconceptsmaremprovided m
thesemaremintended mtombemstartingmpointsmformconsiderationmand mdiscussion,mnot mfinal,mdefi
nitemormuniquemanswers.
Someminternet mwebmsitesmaremsuggested masmexamplemsitesmcontainingmusefulminformation.m
Thesemaremonlymsuggestionsmasmtypicalmstartingmpointsmform morem in-
depthminvestigationmof mthemquestionsmraised.mI mammalwaysmhesitant mtomrefermtominternet mwe
bmsitesmsincemoftenmthemupdatingmof mthem,mand msometimesmtheirmcontinued mexistence,mismp
roblematic.mPerhapsmthembest mwaymtomview mtheminclusionmof mamwebmsiteminmthemSolutionmM
anualmismasmanmindicationmof mquestionsmthat maremmoremopen-
ended mand mmaymrequiremmoremmaterialmthanmisminmthemtext mformpreparingmanswers.
Formthemnew mquantitativemproblemsmand msomemof mthemproblemsmfrommpreviousmeditionsmof
mthemtext mI mhavemused mspreadsheetsmtomproducemsolutions.mThemintent mismtomprovidemthemop
portunitymformusersmof mthemtext mtomcustomizemthesemproblems.mProblemmvariablesmand mvari
ablemvaluesmcanmbemchangesmwithmlittlemeffort.mThemdifficultymismthat mtomprovidemthismcapa
bilitymspecificmsoftwaremmust mbemused msincemwritingmcodemthat mcanmbemused monmmost mcom
putersmismnot mwarranted.mMicrosoft mExcelm97mwasmused.mInmanymcase,mthemsolutionsmaremals
omprovided minmfixed mform.
Somemquestionmanswersmweremput minmthemformmof mtablesmsomthat mit mismpossiblemtomslightlym
manipulatemthemquestions.mFormexample,mvariousmtablemcellsmcanmbemcleared mand mfill-in-
the-
mblankmquestionsmformulated.mMicrosoft mWord m97mwasmused mformthemSolutionmManualmtex
t.
BarneymE.mKlameck
imMarch,m2003
1
, 2
MATERIALS AND PROCESS IN MANUFACTURING
M M M M
Ninth Edition m
E. Paul DeGarmo
m m
J T. Black
m m m
Ronald A. Kohserm m
SolutionsmManualmby
Barney E. Klamecki
m m
Copyright m©m2003mJohnmWileym&mSons,mInc
, Contents
Preface Page 1
Chapterm1 IntroductionmtomMaterialsmand mProcessesminmManufacturing Page 3
Chapterm2 Propertiesmof mMaterials Page 10
Chapterm3 Naturemof mMetalsmand mAlloys Page 20
Chapterm4 EquilibriummPhasemDiagrams mand mthemIron-Carbon mSystem Page 26
Chapterm5 Heat mTreatment Page 34
Chapterm6 FerrousmMetalsmand mAlloys Page 42
Chapterm7 NonferrousmMetalsmand mAlloys Page 49
Chapterm8 NonmetallicmMaterials:mPlastics,mElastomers,mCeramic
s,mand mComposites Page 54
Chapterm9 MaterialmSelection Page 63
Chapterm10mMeasurement mand mInspection Page 72
Chapterm11mNondestructivemInspectionmand mTesting Page 82
Chapterm12mProcessmCapabilitymand mQualitymControl Page 92
Chapterm13mFundamentalsmof mCasting Page 107
Chapterm14mExpendable-Mold mCastingmProcesses Page 116
Chapterm15mMultiple-Use-Mold mCastingmProcesses Page 124
Chapterm16mPowdermMetallurgy Page 131
Chapterm17mFundamentalsmof mMetalmForming Page 140
Chapterm18mHot-Working Page 150
Chapterm19mCold-WorkingmProcesses Page 159
Chapterm20mFabricationmof mPlastics,mCeramics,mand mComposites Page 173
Chapterm21mFundamentalsmof mMachiningm/mOrthogonalmMachining Page 182
Chapterm22mCuttingmToolsmformMachining Page 194
Chapterm23mTurningmand mBoringmand mRelated mprocesses Page 208
Chapterm24mDrillingmand mRelated mHolemMakingmProcesses Page 217
Chapterm25mMilling Page 223
Chapterm26mShaping,mPlaning,mBroaching,mSawing,mand mFiling Page 229
Chapterm27mAbrasivemMachiningmProcesses Page 237
Chapterm28mNontraditionalmMachining Page 242
Chapterm29mWorkholdingmDevices Page 247
Chapterm30mThread mand mGearmManufacturing Page 252
Chapterm31mSurfacemTreatments,mFinishing,mand mIntegrity Page 259
Chapterm32mManufacturingmAutomation Page 267
Chapterm33mRapid mPrototypingmand mFreeformmFabrication Page 283
Chapterm34mMicroelectronicmManufacturingmand mElectronicmAssembly Page 291
Chapterm35mFundamentalsmof mJoining Page 303
Chapterm36mGasmFlamemProcesses Page 308
Chapterm37mArcmprocesses Page 310
Chapterm38mResistancemWeldingmand mOthermWeldingmProcesses Page 316
Chapterm39mBrazingmand mSoldering Page 323
Chapterm40mAdhesivemBondingmand mMechanicalmFastening Page 327
Chapterm41mManufacturingmand mProductionmSystems Page 333
Chapterm42mSystemmand mCellmDesign Page 341
Chapterm43mImplementationmof mLeanmManufacturingmSystemsmand mCells Page 349
, Preface
Thismversionmof mthemtextbookmcontainsmsignificant mnew mcontent mand,msomthen,mdoesmthemSo
lutionmManual.mThesemnotesmaremprovided mtomexplainmsomemaspectsmof mthemnew mcontent.
Themauthorsmof mthemtextbookmprepared mthemnew mcontent mformthembook,mincludingmallmnew m
questionsmand mproblems.mI mprepared monlymthemanswersmtomthemnew mquestionsmand msolution
smformthemnew mproblems.
Manymof mthemquestionsmarembroad,mopen-
ended mand mraisemreal,mpracticalmconcerns.mThemanswersmthat mI mhavemprepared maremintended
mtomdirectlymaddressmthemimportant mconceptsmraised mand mprovidemsomemof mthemthought mpro
cessmleadingmtomthemanswers.mWheremexamplemapplicationsmof mthemconceptsmaremprovided m
thesemaremintended mtombemstartingmpointsmformconsiderationmand mdiscussion,mnot mfinal,mdefi
nitemormuniquemanswers.
Someminternet mwebmsitesmaremsuggested masmexamplemsitesmcontainingmusefulminformation.m
Thesemaremonlymsuggestionsmasmtypicalmstartingmpointsmform morem in-
depthminvestigationmof mthemquestionsmraised.mI mammalwaysmhesitant mtomrefermtominternet mwe
bmsitesmsincemoftenmthemupdatingmof mthem,mand msometimesmtheirmcontinued mexistence,mismp
roblematic.mPerhapsmthembest mwaymtomview mtheminclusionmof mamwebmsiteminmthemSolutionmM
anualmismasmanmindicationmof mquestionsmthat maremmoremopen-
ended mand mmaymrequiremmoremmaterialmthanmisminmthemtext mformpreparingmanswers.
Formthemnew mquantitativemproblemsmand msomemof mthemproblemsmfrommpreviousmeditionsmof
mthemtext mI mhavemused mspreadsheetsmtomproducemsolutions.mThemintent mismtomprovidemthemop
portunitymformusersmof mthemtext mtomcustomizemthesemproblems.mProblemmvariablesmand mvari
ablemvaluesmcanmbemchangesmwithmlittlemeffort.mThemdifficultymismthat mtomprovidemthismcapa
bilitymspecificmsoftwaremmust mbemused msincemwritingmcodemthat mcanmbemused monmmost mcom
putersmismnot mwarranted.mMicrosoft mExcelm97mwasmused.mInmanymcase,mthemsolutionsmaremals
omprovided minmfixed mform.
Somemquestionmanswersmweremput minmthemformmof mtablesmsomthat mit mismpossiblemtomslightlym
manipulatemthemquestions.mFormexample,mvariousmtablemcellsmcanmbemcleared mand mfill-in-
the-
mblankmquestionsmformulated.mMicrosoft mWord m97mwasmused mformthemSolutionmManualmtex
t.
BarneymE.mKlameck
imMarch,m2003
1
, 2
