DeGarmos Materials and Processes in Manufacturing,
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Solutions Manual for DeGarmos Materials and Processes in
Manufacturing, 13th Edition by Black, Ronald Kohser (All
Chapters) A+
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.
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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.
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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.
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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.
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
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