Solution Manual for Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition by Mikell P. Groover

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Solution Manual for Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 5th Edition, by Mikell P. Groover,

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1 INTRODUCTION AND OVERVIEW OF MANUFACTURING 1

1.1 What Is Manufacturing? 2

1.2 Materials in Manufacturing 9

1.3 Manufacturing Processes 11

1.4 Production Systems 18

1.5 Manufacturing Economics 22

1.6 Recent Developments in Manufacturing 27

Part I Material Properties and Product Attributes 36

2 THE NATURE OF MATERIALS 36

2.1 Atomic Structure and the Elements 37

2.2 Bonding between Atoms and Molecules 39

2.3 Crystalline Structures 41

2.4 Noncrystalline (Amorphous) Structures 47

2.5 Engineering Materials 49

3 MECHANICAL PROPERTIES OF MATERIALS 52

3.1 Stress?Strain Relationships 52

3.2 Hardness 67

3.3 Effect of Temperature on Properties 71

3.4 Fluid Properties 73

3.5 Viscoelastic Behavior of Polymers 76

4 PHYSICAL PROPERTIES OF MATERIALS 83

4.1 Volumetric and Melting Properties 83

4.2 Thermal Properties 86

4.3 Mass Diffusion 88

4.4 Electrical Properties 90

4.5 Electrochemical Processes 92

5 DIMENSIONS, SURFACES, AND THEIR MEASUREMENT 95

5.1 Dimensions, Tolerances, and Related Attributes 96

5.2 Measuring Instruments and Gages 97

5.3 Surfaces 106

5.4 Measurement of Surfaces 112

5.5 Effect of Manufacturing Processes 114

Part II Engineering Materials 118

6 METALS 118

6.1 Alloys and Phase Diagrams 119

6.2 Ferrous Metals 124

6.3 Nonferrous Metals 142

6.4 Superalloys 155

7 CERAMICS 159

7.1 Structure and Properties of Ceramics 160

7.2 Traditional Ceramics 163

7.3 New Ceramics 165

7.4 Glass 168

7.5 Some Important Elements Related to Ceramics 172

8 POLYMERS 176

8.1 Fundamentals of Polymer Science and Technology 178

8.2 Thermoplastic Polymers 189

8.3 Thermosetting Polymers 196

8.4 Elastomers 200

8.5 Polymer Recycling and Biodegradability 208

9 COMPOSITE MATERIALS 212

9.1 Technology and Classification of Composite Materials 213

9.2 Metal Matrix Composites 222

9.3 Ceramic Matrix Composites 224

9.4 Polymer Matrix Composites 225

Part III Solidifi cation Processes 230

10 FUNDAMENTALS OF METAL CASTING 230

10.1 Overview of Casting Technology 233

10.2 Heating and Pouring 235

10.3 Solidifi cation and Cooling 239

11 METAL CASTING PROCESSES 251

11.1 Sand Casting 251

11.2 Other Expendable-Mold Casting Processes 257

11.3 Permanent-Mold Casting Processes 263

11.4 Foundry Practice 273

11.5 Casting Quality 277

11.6 Metals for Casting 279

11.7 Product Design Considerations 281

12 GLASSWORKING 287

12.1 Raw Materials Preparation and Melting 287

12.2 Shaping Processes in Glassworking 288

12.3 Heat Treatment and Finishing 294

12.4 Product Design Considerations 295

13 SHAPING PROCESSES FOR PLASTICS 297

13.1 Properties of Polymer Melts 299

13.2 Extrusion 301

13.3 Production of Sheet and Film 311

13.4 Fiber and Filament Production (Spinning) 314

13.5 Coating Processes 315

13.6 Injection Molding 316

13.7 Compression and Transfer Molding 327

13.8 Blow Molding and Rotational Molding 328

13.9 Thermoforming 334

13.10 Casting 338

13.11 Polymer Foam Processing and Forming 339

13.12 Product Design Considerations 341

14 PROCESSING OF POLYMER MATRIX COMPOSITES AND RUBBER 348

14.1 Overview of PMC Processing 349

14.2 Open Mold Processes 352

14.3 Closed Mold Processes 356

14.4 Other PMC Shaping Processes 359

14.5 Rubber Processing and Shaping 364

14.6 Manufacture of Tires and Other Rubber Products 369

Part IV Particulate Processing of Metals and Ceramics 375

15 POWDER METALLURGY 375

15.1 Characterization of Engineering Powders 377

15.2 Production of Metallic Powders 381

15.3 Conventional Pressing and Sintering 383

15.4 Alternative Pressing and Sintering Techniques 390

15.5 Materials and Products for Powder Metallurgy 393

15.6 Design Considerations in Powder Metallurgy 394

16 PROCESSING OF CERAMICS AND CERMETS 400

16.1 Processing of Traditional Ceramics 401

16.2 Processing of New Ceramics 408

16.3 Processing of Cermets 411

16.4 Product Design Considerations 413

Part V Metal Forming and Sheet Metalworking 416

17 FUNDAMENTALS OF METAL FORMING 416

17.1 Overview of Metal Forming 416

17.2 Material Behavior in Metal Forming 419

17.3 Temperature in Metal Forming 421

17.4 Strain Rate Sensitivity 423

17.5 Friction and Lubrication in Metal Forming 425

18 BULK DEFORMATION PROCESSES IN METAL WORKING 429

18.1 Rolling 430

18.2 Other Deformation Processes Related to Rolling 438

18.3 Forging 440

18.4 Other Deformation Processes Related to Forging 452

18.5 Extrusion 457

18.6 Wire and Bar Drawing 468

19 SHEET METALWORKING 481

19.1 Cutting Operations 482

19.2 Bending Operations 488

19.3 Drawing 493

19.4 Other Sheet-Metal-Forming Operations 500

19.5 Dies and Presses for Sheet-Metal Processes 503

19.6 Sheet-Metal Operations Not Performed on Presses 510

19.7 Bending of Tube Stock 516

Part VI Material Removal Processes 522

20 THEORY OF METAL MACHINING 522

20.1 Overview of Machining Technology 524

20.2 Theory of Chip Formation in Metal Machining 528

20.3 Force Relationships and the Merchant Equation 532

20.4 Power and Energy Relationships in Machining 538

20.5 Cutting Temperature 540

21 MACHINING OPERATIONS AND MACHINE TOOLS 548

21.1 Machining and Part Geometry 548

21.2 Turning and Related Operations 552

21.3 Drilling and Related Operations 561

21.4 Milling 566

21.5 Machining Centers and Turning Centers 574

21.6 Other Machining Operations 576

21.7 Machining Operations for Special Geometries 581

21.8 High-Speed Machining 589

22 CUTTING-TOOL TECHNOLOGY 596

22.1 Tool Life 596

22.2 Tool Materials 603

22.3 Tool Geometry 613

22.4 Cutting Fluids 623

23 ECONOMIC AND PRODUCT DESIGN CONSIDERATIONS IN MACHINING 632

23.1 Machinability 632

23.2 Tolerances and Surface Finish 635

23.3 Selection of Cutting Conditions 639

23.4 Product Design Considerations in Machining 646

24 GRINDING AND OTHER ABRASIVE PROCESSES 653

24.1 Grinding 653

24.2 Related Abrasive Processes 671

25 NONTRADITIONAL MACHINING AND THERMAL CUTTING PROCESSES 678

25.1 Mechanical Energy Processes 679

25.2 Electrochemical Machining Processes 683

25.3 Thermal Energy Processes 687

25.4 Chemical Machining 696

25.5 Application Considerations 702

Part VII Property Enhancing and Surface Processing Operations 709

26 HEAT TREATMENT OF METALS 709

26.1 Annealing 710

26.2 Martensite Formation in Steel 710

26.3 Precipitation Hardening 714

26.4 Surface Hardening 716

26.5 Heat Treatment Methods and Facilities 717

27 SURFACE PROCESSING OPERATIONS 721

27.1 Industrial Cleaning Processes 722

27.2 Diffusion and Ion Implantation 726

27.3 Plating and Related Processes 728

27.4 Conversion Coating 732

27.5 Vapor Deposition Processes 734

27.6 Organic Coatings 740

27.7 Porcelain Enameling and Other Ceramic Coatings 743

27.8 Thermal and Mechanical Coating Processes 744

Part VIII Joining and Assembly Processes 748

28 FUNDAMENTALS OF WELDING 748

28.1 Overview of Welding Technology 750

28.2 The Weld Joint 753

28.3 Physics of Welding 755

28.4 Features of a Fusion-Welded Joint 760

29 WELDING PROCESSES 765

29.1 Arc Welding 765

29.2 Resistance Welding 776

29.3 Oxyfuel Gas Welding 783

29.4 Other Fusion-Welding Processes 787

29.5 Solid-State Welding 790

29.6 Weld Quality 796

29.7 Weldability 800

29.8 Design Considerations in Welding 801

30 BRAZING, SOLDERING, AND ADHESIVE BONDING 807

30.1 Brazing 807

30.2 Soldering 814

30.3 Adhesive Bonding 818

31 MECHANICAL ASSEMBLY 825

31.1 Threaded Fasteners 826

31.2 Rivets and Eyelets 833

31.3 Assembly Methods Based on Interference Fits 834

31.4 Other Mechanical Fastening Methods 838

31.5 Molding Inserts and Integral Fasteners 839

31.6 Design for Assembly 841

Part IX Special Processing and Assembly Technologies 847

32 RAPID PROTOTYPING AND ADDITIVE MANUFACTURING 847

32.1 Fundamentals of Rapid Prototyping and Additive Manufacturing 849

32.2 Additive Manufacturing Processes 852

32.3 Cycle Time and Cost Analysis 860

32.4 Additive Manufacturing Applications 864

33 PROCESSING OF INTEGRATED CIRCUITS 869

33.1 Overview of IC Processing 871

33.2 Silicon Processing 874

33.3 Lithography 879

33.4 Layer Processes Used in IC Fabrication 883

33.5 Integrating the Fabrication Steps 890

33.6 IC Packaging 892

33.7 Yields in IC Processing 898

34 ELECTRONICS ASSEMBLY AND PACKAGING 904

34.1 Electronics Packaging 904

34.2 Printed Circuit Boards 906

34.3 Printed Circuit Board Assembly 915

34.4 Electrical Connector Technology 923

35 MICROFABRICATION TECHNOLOGIES 928

35.1 Microsystem Products 928

35.2 Microfabrication Processes 935

36 NANOFABRICATION TECHNOLOGIES 945

36.1 Nanotechnology Products and Applications 946

36.2 Introduction to Nanoscience 951

36.3 Nanofabrication Processes 955

Part X Manufacturing Systems 964

37 AUTOMATION TECHNOLOGIES FOR MANUFACTURING SYSTEMS 964

37.1 Automation Fundamentals 965

37.2 Hardware for Automation 968

37.3 Computer Numerical Control 973

37.4 Industrial Robotics 986

38 INTEGRATED MANUFACTURING SYSTEMS 997

38.1 Material Handling 997

38.2 Fundamentals of Production Lines 1000

38.3 Manual Assembly Lines 1002

38.4 Automated Production Lines 1006

38.5 Cellular Manufacturing 1011

38.6 Flexible Manufacturing Systems and Cells 1016

38.7 Computer Integrated Manufacturing 1022

Part XI Manufacturing Support Systems 1028

39 PROCESS PLANNING AND PRODUCTION CONTROL 1028

39.1 Process Planning 1030

39.2 Other Manufacturing Engineering Functions 1038

39.3 Production Planning and Control 1042

39.4 Just-In-Time Delivery Systems 1049

39.5 Lean Production 1052

40 QUALITY CONTROL AND INSPECTION 1058

40.1 Product Quality 1058

40.2 Process Capability and Tolerances 1059

40.3 Statistical Process Control 1061

40.4 Quality Programs in Manufacturing 1066

40.5 Inspection Principles 1072

40.6 Modern Inspection Technologies 1075