Solutions Manual For DeGarmos Materials and Processes in Manufacturing 13th Edition By Black, Ronald Kohser (All Chapters)

Solutions Manual H H




for DeGarmos Ma
H H




terials and Proces H H




ses in Manufactur
H H




ing, 13e Black, Ro
H H H




nald Kohser (All C
H H H




hapters)

, CHAPTERH1
IntroductionHtoHDeGarmo’sHMaterialsHandHProcessesHinHManufacturing


ReviewHQuestions

1. TheHavailabilityHandHcostHofHmanufacturedHproductsHareHanHimportantHpartHofHourHco
stHofHlivingHandHtheHrealHwealthHofHtheHnation.HThus,HreducingHtheHcostHofHproducerHandHc
onsumerHgoodsHimprovesHtheHproductivityHwhileHholdingHdownHinflation,HtherebyHimpro
vingHtheHgeneralHstandardHofHliving.

2. ThisHisHtrueHifHyouHconsiderHthatHeveryoneHwhoHusesHtheHoutputHfromHaHprocess,Hin
cludingHallHtheHintermediateHsteps,HisHaHcustomer.H TheHoperatorHofHtheHnextHprocessHisHtheH
userHandHcustomerHofHtheHproceedingHprocess.HInHfact,HsomeHcompaniesHidentifyHtwoHcu
stomers,HtheHexternalHcustomerHwhoHbuysHtheHfinishedHproductHandHtheHinternalHcustom
er,HwhoHbuildsHtheHproductHoneH-
Hi.e.,HtheHpeopleHwhoHworkHinHtheHmanufacturingHsystem.




3. JobHshopH-
HanHinjectionHmoldHmanufacturingHshop,HtheHshopHatHaHlargeHuniversityHthatHproduces Hrese

archHequipmentHandHapparatus.H JobHshopsHareHcapableHofHproducingHproductsHwithHgreatHv
ariety,HtypicallyHemployingHhighlyHskilledHworkers.

FlowHshopH–
HautomobileHassembly. HFlowHshopsHareHusuallyHlaidHoutHsoHthatHspecificHproductsHpa

ssHthroughHaHseriesHofHoperationsHwithHnoHbackflow.H TheHproductHrangeHisHlimited,Hp
roductionHvolumeHisHlargeHandHlaborHskillHisHlowerHthanHinHjobHshops.

ProjectHshopH–Hdiesel-
electricHlocomotiveHproductionHfacility.H TheHendHproductHisHveryHlargeHandHsoHmanyH
machines,HtoolsHandHpeopleHcomeHtoHtheHproductHtoHproduceHitHatHaHrelativelyHfixedHlo
cation.

TheHSubwayHsandwichHshopHwouldHbeHaHflowHshop.

4. InHtheHcontextHofHmanufacturing,HaHmanufacturingHsystemHisHaHcollectionHofHmen,H
machineHtools,HandHmaterial-
movingHsystems,HcollectedHtogetherHtoHaccomplishHspecificHmanufacturingHorHfabricati
onHsequences,HresultingHinHcomponentsHorHendHproducts.H TheHmanufacturingHsystemHis
HbackedHupHbyHandHsupported HbyHtheHproductionHsystem,HwhichH includesHfunctionsHlikeH
controlHofHquality,Hinventory,Hproduction,HandHmanpower,HasHwellHasHscheduling,Hplanni
ngHandHtheHlike.HWithinHtheHmanufacturingHsystem,HthereHwillHbeHmachineHtools,Hwhic
hHcanHperformHjobsHor

5. No.HTheHcuttingHtoolHisHtheHimplementHthatHdoesHtheHcutting.HItHcontainsHtheHcuttin
gHedgeHandHisHusedHinHtheHmachineHtool.HHTheHmachineHtoolHdrivesHtheHcuttingHtoolHthr
oughHtheHworkHmaterial.


1

,6. TheHbasicHmanufacturingHprocessesHare:HcastingHorHmolding,Hforming,H(hea
t)Htreating,HmetalHremoval,Hfinishing,HjoiningH(welding),Hassembly,HandHinspecti
on.




2

, 7. CastingHcouldHbeHused,HprovidedHtheHmaterialHcanHbeHmeltedHandHpouredHinHtheHapp
ropriateHprocess.HByHcasting,HtheHdesiredHshapedHinHfinalHorHnear-
finalHform,HcouldHbeHobtained.HThisHgreatlyHreducesHtheHnecessityHforHmachiningHtheHha
rd-to-
machineHmetal.HLessHmachiningHisHneededHwhenHtheHrawHmaterialHshapeHisHcloseHtoHthe
HfinishedHpartHsizeH
andHshapeH(calledHnearHnetHshapeHcasting).HTheHpartHcouldHalsoHbeHm
adeHinHsimplerHsegmentsHandHassembledHorHjoined.

8. TheHwaxHpatternHisHmeltedHandHremovedHasHaHliquid.HAnyHremainingHwaxHisHthe
nHvaporizedHwhenHtheHmoldHisHheatedHinHpreparationHforHtheHpour.

9. AHrelief-
imageHisHtheHcavityHinHtheHdieHthatHtheHworkHmaterialHisHdeformedHintoHwhenHtheHdieHisH
pressedHintoHtheHworkpiece.H MaterialHonHtheHworkpieceHmovingHintoHtheHcavity,H“conca
ve,”HofHtheHdieHresultsHinHtheHraised,H“convex,”HpartHofHtheHmedalHsurface.

10. TrainsHstopHatHtheHstationHtoHloadHandHunloadHpeopleHandHmaterials.HInHanHassemblyHli
ne,HproductsHstopHatHstationsHtoHtakeHonHmaterialsHorHhaveHoperationsHperformedHonHthem.

11. False.HStorageHisHveryHexpensiveHbecauseHtimeHcostsHtheHcompanyHmoney.HItHisH
expensiveHtoHkeepHtrackHofHstoredHmaterials,HtoHputHthemHintoHstorage,HtoHgetHthemHba
ckHfromHstorage,HtoHdamageHthemHasHaHresultHofHexcessiveHhandling,HandHsoHon.HMor
eHimportantly,HstorageHusuallyHaddsHnoHvalueH-
HveryHfewHitems HappreciateHonHtheHshelf.




12. ForHtheHsimple,HconventionalHpaperHclip,HformingHprocessesHareHfirstHusedHtoHmakeHa
ndHcoatHwire,HwhichHisHthenHcutHtoHlengthHandHformedHinHthreeHbendingHoperations.

13. ToolsHareHusedHtoHhold,Hcut,Hshape,HorHformHtheHunfinishedHproduct.HCommonHhand
HtoolsHincludeHtheHsaw,Hhammer,Hscrewdriver,Hchisel,Hpunch,Hsandpaper,Hdrill,Hclamp,Hfi

le,Htorch,HandHgrindstone.HBasically,HmachinesHareHmechanizedHversionsHofHsuchHhandHt
oolsHandHareHcalledHcuttingHtools.HSomeHexamplesHofHtoolsHforHcuttingHareHdrillHbits,Hrea
mers,Hsingle-
pointHturningHtools,HmillingHcutters,HsawHblades,Hbroaches,HandHgrindingHwheels.HNonc
uttingHtoolsHforHformingHincludeHextrusionHdies,Hpunches,HandHmolds.HToolsHalsoHinclud
eHworkholders,Hjigs,HandHfixtures.HTheseHtoolsHandHcuttingHtoolsHareHgenerallyHreferredHt
oHasHtheHtooling,HwhichHusuallyHmustHbeHconsideredH(purchased)HseparateHfromHmachin
eHtools.

14. InefficientHisHaHrelativeHtermHhere.HIfHweHcanHeliminateHmachining,HweHcanHsaveHtheHt
imeHandHtheHmoney.HMachiningHprocessesHareHgenerallyHthoseHwhichHgiveHtheHpartHitsHfi
nalHsize,Hshape,HandHsurfaceHfinishHandHaddHvalueHtoHtheHpart.HBecauseHtheyHdoHnotHprod
uceHtheHshapeHandHsizeHinHbulk,HbutHratherHbyHlocalizedHactionHtheyHmayHnotHbeHasHeffici
entHasHformingHandHcastingHprocesses.HCuttingHtoolHandHworkholdingHtoolingHexpensesH
mayHalsoHbeHreduced,HsinceHtheHsameHtoolHcanHworkHonHmanyHdifferentHproducts.

15. FigureH1-1HandHfigureH1-
16HbothHshowHlifeHcycleHprogressions.H ForHanHaudiocassetteHtape,HitHwentHtoHaHcommod
ityHproduct,HandHisHnowHinHdeclineHasHCD’sHareHtakingHover.HWeHwillHknowHthatHitHisHin
3