Fundamentos de Manufactura Philip Rufe 2 Ed

Fundamentals
ofManufacturing
Philip D. Rufe, CMfgE
Editor
Second Edition
Solutions Manual
Society of
Manufacturing
Engineers
www.sme.org
Copyright 2002 Society of Manufacturing Engineers

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Printed in the United States of America
PREFACE
The purpose of this manual is to show how to solve the review questions found in the book
Fundamentals of Manufacturing, 2nd edition. The Fundamentals of Manufacturing Solutions
Manual is also intended to help instructors teach individuals studying for the Fundamentals of
Manufacturing Technologist (CMfgT) certification exam.
Detailed answers are provided for the quantitative review questions. For the qualitative review questions, the manual directs readers to the location in the book where the answer can be
found.
Fundamentals of Manufacturing Solutions Manual

Solution 1.1
3x + 2 = 4 x 6 + x
3 x 4 x x = 6 2
2 x = 8
x=4
Solution 1.2
1
2 3
1
x = x+
6
3 4
2
2 3
1
1
12 x = x +
3 4
2
6
2x 8 = 9x + 6
2x 9x = 6 + 8
7 x = 14
x = 2
Solution 1.3
x
= 2x + 3
y
x
y = 2 x + 3
y
x = 2 xy + 3 y
x 2 xy = 3 y
x(1 2 y ) = 3 y
x=
3y
1 2y
Solution 1.4
3
2
1
=
x x 1 2x
2
1
3
2 x( x 1)
=
x x 1 2x
(2 x 2)(3) (2 x )(2) = ( x 1)(1)
6x 6 4x = x 1
6 x 4 x x = 1 + 6
x=5
Page 1 of 65
Solution 1.5
l = 2 w 4 ft
P = l + l + w + w = 46 ft
2(2w 4 ft) + 2w = 46 ft
4w 8 ft + 2w = 46 ft
6w = 54 ft
w = 9 ft
Solution 1.6
x = 4th test grade
0.83 + 0.76 + 0.79 + x
= 0.80
4
0.83 + 0.76 + 0.79 + x
4
= 0.80
4
0.83 + 0.76 + 0.79 + x = 3.20

x = 3.20 0.83 0.76 0.79
x = 0.82 = 82%
Solution 1.7
y 2 + 5 y = 5
y2 + 5 y + 5 = 0
b b 2 4ac
2a
a =1
y=
b=5
c=5
5 52 4(1)(5)
2(1)
x = 1.382, 3.618
x=
Page 2 of 65

Solution 1.8
( g + 2)( g 3) = 1
g 2 3g + 2 g 6 = 1
g2 g 7 = 0
b b 2 4ac
2a
a =1
g=
b = 1
c = 7
(1) (1) 2 4(1)(7)
2(1)
g = 3.193, 2.193
g=
Solution 1.9
6r 2 = 7 19r
6r 2 + 19r 7 = 0
b b 2 4ac
2a
a=6
r=
b = 19
c=7
19 192 4(6)(7)
2(6)
r = 0.333, 3.5
r=
Solution 1.10
A3 = 40x
x
x
40 ft
A2 = (30 + 2x)x
30 ft
A1 = (30 + 2x)x
x
A4 = 40x
Page 3 of 65

Achips = 296 ft 2
2 [(30 + 2 x) x ] + 2 [40 x ] = 296
60 x + 4 x 2 + 80 x = 296
4 x 2 + 140 x 296 = 0
b b 2 4ac
2a
a=4
x=
b = 140
c = 296
140 1402 4(4)(296)
2(4)
x = 2 ft (only valid solution)
x=
Solution 1.11
l
l 4 in.
2 2 in.
squares
Volumebox = length width height = 256 in.3

(l 4)(l 4 4)(2) = 256
(l 4)(l 8)(2) = 256
(l
12l + 32 ) 2 = 256
2l 2 24l + 64 = 256
2l 2 24l 192 = 0
b b 2 4ac
2a
a=2
l=
b = 24
c = 192
(24) (24) 2 4(2)(192)
17.49 in.
2(2)
w = 17.49 in. 4 in. = 13.49 in.
l=
Page 4 of 65
Solution 1.12
2x + 3y = 5
2x + 2 y = 5
2x + 3y = 5
1(2 x + 2 y = 5)
2x + 3y = 5
2 x 2 y = 5
y=0
2 x + 3(0) = 5
x = 2.5
Solution 1.13
3x 2 y = 5
4 x + 5 y = 5
4(3 x 2 y = 5)
3(4 x + 5 y = 5)
12 x 8 y = 20
12 x + 15 y = 15
7 y = 35
y=5
3 x 2(5) = 5
3 x = 15
x=5
Page 5 of 65
Solution 1.14
x 2y + z = 5
2x + 3y + z = 1
x + 3y + 2z = 2
Convert the equations into an augmented matrix.
1 2 1 5
2 3 1 1

1
3 2 2
Arrange the rows so the leading entries are in decreasing order.
3 2 2
1
1 2 1 5

2 3 1 1
Replace the third row with the sum of itself and 2 times the second row.
1
3
2 2
1
1 5
2
2 + 2(1) 3 + 2(2) 1 + 2(1) 1 + 2(5)

1 3 2 2
1 2 1 5

0 1 3 11
Replace the second row with the sum of 1 times itself and the first row.
3
2
2
1
1(1) + 1 1(2) + 3 1(1) + 2 1(5) + 2
0
1
3 11
1 3 2 2
0 5 1 3

0 1 3 11
Replace the third row with the sum of 5 times itself and the second row.
1
0
0
1
0
2
5
1 3
5(1) + 5 5(3) + 1 5(11) 3
3 2 2
5 1 3
0 16 52
3
Page 6 of 65
Convert the matrix back into equation form.

x + 3y + 2z = 2
5y + z = 3
16z = 52
z=
52 13
=
16 4
13
= 3
4
12 13
5y =
4 4
1 25
5
y=
=
5 4
4
5y +
5
13
x + 3 + 2 = 2
4
4
8 15 26
3
x= +
=
4 4
4
4
Solution 1.15
25 x = 125
log 25 x = log125
x log 25 = log125
x=
log125
log 25
x = 1.5
Solution 1.16
log 2 x = 3
2log2 x = 23
x =8
Page 7 of 65

Solution 1.17
log10 x + log10
3x
=5
2
3x
log10 x = 5
2
3x 2
log10
=5
2
10
log10
3 x2
2
= 105
3x 2
= 100,000
2
2(100,000)
x2 =
3
200,000
3
x = 258.2
x=
Solution 1.18
d = 10 m
h = 10 m
Acylinder = (d )(h) = (10 m)(10 m) = 314.2 m 2
Atop = ( r ) 2 = (5 m) 2 = 78.5 m 2
Atotal = Acylinder + Atop = 314.2 m 2 + 78.5 m 2 = 392.7 m 2
Paint needed =
1L
(392.7 m 2 ) = 78.5 L
5 m2
Solution 1.19
y = mx + b
m = 2
y = 0 at x = 2
y = 2 x + b
0 = 2(2) + b
b=4
y = 2 x + 4
Page 8 of 65

Solution 1.20
x y
+ =1
a b
a=4
b = 6
x y
+
=1
4 6
x y
12 +
= 1
4 6
3 x 2 y = 12
2 y = 3 x 12
y=
3
x6
2
Solution 1.21
cos = 0.8
= cos 1 0.8
36.87
Solution 1.22
4
3
c = hypotenuse
a=3
b=4
c2 = a2 + b2
c = 32 + 42
c=5
Page 9 of 65

Solution 1.23
C
4
A
2
a=4
b=3
c=2
a 2 = b 2 + c 2 2bc cos A
a 2 b2 c2
A = cos 1
2bc
42 32 22
A = cos 1
2(3)(2)
= 104.5
b 2 = a 2 + c 2 2ac cos B
b2 a 2 c2
B = cos 1
2ac
32 42 22
B = cos 1
= 46.6
2(4)(2)
C = 180 A B
C = 180 104.5 46.6 = 28.9
Page 10 of 65

Solution 1.24
C
a
B
60
8
A = 60
a=?
b=6
c =8
a 2 = b 2 + c 2 2bc cos A
a = 62 + 82 2(6)(8) cos 60
a = 7.2
Solution 1.25
a) P(seven) =
4 possible sevens 4
1
=
=
52 cards
52 13
b) P(red seven) =
c) P(spade) =
2 possible red sevens 2

1
=
=
52 cards
52 26
13 possible spades 13 1
=
=
52 cards
52 4
d) P(seven of spades) =
e) P(face card) =
1 possible seven of spades 1

=
52
52 cards
12 possible face cards 12 3

=
=
52 cards
52 13
Page 11 of 65

Solution 1.26
Permutations of the numbers 1 through 6 taking two at a time:
P(6,2) =
6!
= 30
(6 2)!
With dice, it is also possible to roll a 1-1, 2-2, 3-3, 4-4, 5-5, and 6-6.
Therefore, the possible outcomes of rolling dice = 30 + 6 = 36.
a) P(seven) =
6 ways to make a seven 6 1

=
=
36 possible outcomes
36 6
1 way to make a two 35

=
36 possible outcomes 36
18 ways to make an odd sum 18 1
c) P(odd sum) =
=
=
36 2
36 possible outcomes
b) P(greater than two) = P(not two)=1 P(two)=1
Solution 1.27
P (6,6) =
6!
= 720
(6 6)!
Solution 1.28
C (30,3) =
30!
= 4,060
3!(30 3)!
Solution 1.29
Getting a head with the first coin does not affect the outcome of the other coin.
Therefore, they are independent events.
1 1 1
=
2 2 4
1 1 1
P(T and T) = =
2 2 4
P(H and H) =
Getting two heads and two tails with one toss is impossible. Therefore, those events are
mutually exclusive.
P(H and H or T and T) =
1 1 1
+ =
4 4 2
Page 12 of 65

Solution 1.30
Mode = most frequent score = 75
=
1(35) + 3(45) + 6(55) + 8(65) + 10(75) + 4(85) + 2(95)

= 67.65 67.7
1 + 3 + 6 + 8 + 10 + 4 + 2
34
2
i
N 2
34
2
i
= 1(352 ) + 3(452 ) + 6(552 ) + 8(652 ) + 10(752 ) + 4(852 ) + 2(952 ) = 162, 450
N = 34
162, 450 34(67.652 )

= 14.2
34
Solution 1.31
0.496 0.497
= 0.25
0.004
0.504 0.497
z2 =
= 1.75
0.004
A2 A1 = 0.9599 0.4013 = 0.5586 = 55.9%
z1 =
Solution 1.32
f ( x) = 3x5 + 7 x 2
d (kx n )
= nkx n 1
dx
f ( x) = 5(3 x 51 ) + 2(7 x 21 ) = 15 x 4 + 14 x
f ( x) =
Solution 1.33
y = 2 x3 3x
dy d (kx n )
=
= nkx n 1
dx
dx
y = 3(2 x 31 ) 1(3 x1 0 ) = 6 x 2 3
y =
Slope x =1 = 6(1) 2 3 = 3
Page 13 of 65

Solution 1.34
y = x 3 12 x 2
dy d (kx n )
=
= nkx n 1
dx
dx
y = 3( x 31 ) 2(12 x 2 1 ) = 3x 2 24 x
y = 3 x( x 8)
y =
y = 0 when x = 0,8
y = 2(3 x 2 1 ) 1(24 x1 0 ) = 6 x 24
y (0) = 6(0) 24 = 24
y (8) = 6(8) 24 = 24
Local maximum at x = 0
Local minium at x = 8
Solution 1.35
y = 4 x3
b
A = f ( x)dx
a
a =1
b=2
cf ( x)dx = c f ( x)dx
x n +1
x dx = n + 1 + C
n
c=4
n=3
2
2
2
x 3+1
3
4 2
=
=
A 4 x dx 4 x 3 dx = 4
=x 1
3 +1 1
1
1
2
A = x 4 = 24 14 = 15
1
Solution 2.1
1,000 mm
5 m
= 5,000 mm
1m
Page 14 of 65

Solution 2.2
From page 27, it can be inferred that if the millimeter is used as the standard of length for
most drafting operations, it would be commonly used for machining practices.
Solution 2.3
2.54 102 m 1,000 mm
1 in.
= 25.4 mm
1 in.
1m
Solution 2.4
cycles 1 Hz
50
=50 Hz
sec 1 cycle
sec
Solution 2.5
1 ft
1 m
=3.28 ft
1
3.048 10 m
Solution 2.6
From Table 2-5, the Pascal (Pa) is the SI symbol used to represent pressure.
Solution 2.7
From Table 2-5, the Joule (J) is the SI symbol used to represent energy.
Solution 2.8
0.022
in.
mm
25.4 mm
=0.559
rev 1 in.
rev
Solution 3.1
From Figure 3-1, the frequency of visible light is higher than the frequency of FM radio.
Solution 3.2
From Figure 3-2, the longest wavelength of light that can be seen with the human eye is
approximately 670 109 meters.
Page 15 of 65

Solution 3.3
From Figure 3-1, at 880 nanometers, the light is not in the visible spectrum.
c = f
m
s
9
= 880 10 m
c = 300 106
6 m
c 300 10
s =3.411014 Hz
f = =
880 10 9 m
Solution 3.4
From Figure 3-2, the eye is more sensitive to green than blue. Therefore, green would be
a better choice for safety.
Solution 3.5
Wall
7m
= 41.19
8m
2 = 1 = 41.19
1 = tan 1
y
12 m
y = 12 m(tan 41.19) = 10.5 m
tan 41.19 =
x = 3 m + y = 3 m + 10.5 m = 13.5 m
Page 16 of 65

Solution 3.6
1 = 30
1( water ) = 1.33
2(air ) = 1
1 sin 1 = 2 sin 2
1.33sin 30 = 1sin 2
1.33sin 30
2 = sin 1
= 41.68
1
3 = 90 41.68 = 48.32
tan 60 =
3m
x
3m
= 1.73 m
tan 60
y = 3 m 1.73 m = 1.27 m
x=
z
1.27 m
z = 1.27 m (tan 48.32) = 1.4 m
tan 48.32 =
Solution 4.1
From Figure 4-2, the lowest intensity of sound at 10,000 Hz that can be detected by the
typical human ear is approximately 30 dB.
Solution 4.2
From Figure 4-2, the loudest (highest intensity) sound that occurs in typical human
speech is approximately 70 dB, with a frequency of approximately 600 Hz. It can also be
viewed as being closer to 75 dB.
Page 17 of 65

Solution 4.3
I
Relative intensity = 10log
I0
Relative intensity = 80 dB
W
m2
I 0 = 1012
I =?
I
80 dB = 10log
1012 W2
m
I
80 dB
= log
10
12 W
10
m2
108 = 10
108 =
log
1012 W
2
m
I
1012
W
m2
W
W
I = 108 1012 2 = 104 2

m
m
Solution 4.4
I
I0
W
I = 4 106 2
m
W
I 0 = 1012 2
m
6 W
4 10 m 2
1012 W2
m
= 66 dB
Page 18 of 65

Solution 4.5
I
I0
Relative intensity = 90 dB
W
m2
I 0 = 1012
I
90 dB = 10log
1012 W2
m
I
90 dB
= log
10
1012 W2
m
109 = 10
109 =
log
1012 W
m2
I
1012
W
m2
W
W
I = 109 1012 2 = 103 2

m
m
W
P = IA = 103 2 ( 2 m 4 m ) = 8 103 W
m
Solution 4.6
rpm wheel = 60
miles 63,360 in.

1 hr
1 rev
= 1,121 rpm
hr
1 mile
60 min (18 in.)
pitch = 1,121
rev 1 min 5 slots or cycles
93 Hz
min 60 sec
rev
Solution 5.1
I = 2 amps
V = 12 volts
P = IV = 2 amps (12 volts) = 24 W
Page 19 of 65

Solution 5.2
V = 12 volts
R = 100 ohms
I=
V
12 volts
=
= 0.12 amps
R 100 ohms
Solution 5.3
P = 1,000 W
V = 110 volts
P = IV
I=
P 1,000 W
=
= 9.1 amps
V 110 volts
V
R
V 110 volts
R= =
= 12.1 ohms
I 9.1 amps
I=
Solution 5.4
From page 42, kilowatt-hours measure electrical energy.
Solution 5.5
From Figure 5-3, the equivalent voltage of two batteries connected in series is the sum of
the two battery voltages. Therefore, to achieve a supply voltage of three volts, the two
1.5-volt batteries should be connected in series.
Page 20 of 65

Solution 5.6
Page 21 of 65

Solution 5.7
Solution 6.1
M A = Pa + R (a + b) = 0
R (a + b) = Pa
R=
Pa
a+b
Solution 6.2
Fy = 40 lb 20 lb 40 lb + Fbeam = 0
Fbeam = 40 lb + 20 lb + 40 lb = 100 lb
Page 22 of 65
Solution 6.3
M A = [T sin 30(5 ft) ] [500 lb(5 ft) ] = 0

500 lb (5 ft)
5 ft
500 lb
T=
= 1,000 lb
sin 30
T sin 30 =
Solution 6.4
Two forces of equal magnitude and opposite sense with parallel lines of action form a
couple as illustrated in Figure 6-7.
M = Fd
M = 100 N sin 45(2 m) = 141.4 N-m
The moment must be clockwise to keep the beam in equilibrium.
Page 23 of 65

Solution 6.5
W down the plane = 100 lb sin 30 = 50 lb

Friction = f = uN = 0.25 N
Fy = 100 lb cos30 + N = 0
N = 100 lb cos30 = 86.6 lb
f = 0.25(86.6 lb) = 21.7 lb
Weight down the plane (50 lb) > friction force (21.7 lb)
Block will slide down the plane.
Solution 6.6
Tilting the coordinate system makes the problem easier.

m
W = 50 kg 9.81 2 = 490.5 N
s
Fx = P + f 490.5 N sin 45 = 0
P + uN 346.8 N = 0
P = 0.3( N ) + 346.8 N
Fy = N 490.5 N cos 45 = 0
N = 490.5 N cos 45 = 346.8 N
P = 0.3(346.8 N) + 346.8 N=243 N
Page 24 of 65

Solution 7.1
m
s
m
a = 5 2
s
v=0
v0 = 30
s =?
v 2 = v0 2 + 2as
2
m
m
0 = 30 + 2 5 2 s
s
s
2
900 m 2
s = 90 m
s=
10 m 2
s
2
Solution 7.2
The time for the particle to reach its maximum height is the same as the time for it to
return. If desired, this can be verified using Equations 7-3 and 7-5.
m
s
v = 0 (velocity at particles maximum height)
v0 = 50
a = 9.81
m
s2
t =?
v = v0 + at
m
m
9.81 2 (t )
2
s
s
m
50
s = 5.1 s
t=
m
9.81
s2
0 = 50
Total travel time = 2t = 2 (5.1 s ) = 10.2 s
Page 25 of 65

Solution 7.3
rad
s2
t = 10 s
0 = 0
=6
=?
= 0 t +
= 0(t ) +
t 2
2
6 rad
(10 s )
= 300 rad
2
1 rev
300 rad
= 47.8 rev
2 rad
Solution 7.4
1.5 ft
0 = 0.5
rad
s
rad
s2
ft
v = 10
s
t =?
= 0 + t
=1
v = 2r
t=
t=
10 ft
v
s = 1.1 rev 2 rad = 6.7 rad
=
2r 2(1.5ft)
s rev
s
6.7 rad 0.5 rad

s
s = 6.2 s
1 rad s 2
Page 26 of 65

Solution 7.5
W = 7 lb
m=
7 lb
32.2 ft
= 0.217 slugs
2
s
ft 1 min
ft
v = 300
=5
min 60 s
s
1
K E = mv 2
2
2
KE =
1
ft
(0.217 slugs ) 5 = 2.7 ft-lb
2
s
Solution 7.6
F = kx
W lb = k (1 in.)
k=
lb
W lb
=W
1 in.
in.
PEweight = mgh = Wh
1
PEspring = kx 2
2
PEweight = PEspring
1
lb 2
W lb(10 in.) = W
( x)
2
in.
2(W lb)(10 in.)
x2 =
lb
W
in.
x = 20 in.2 = 4.5 in.
Solution 8.1
P = 2,000 lb
d = 0.750 in.
d 2
4
P
2,000 lb
= =
= 4,527 psi
A (0.750 in.) 2
4
A=
Page 27 of 65

Solution 8.2
Fs = 2
y (steel) = 36,000 psi
y
Fs =
a =
y
Fs
36,000 psi
= 18,000 psi
2
Solution 8.3
12 in.
L = 50 ft
= 600 in.
1 ft
P = 200 lb
L = 0.5 in.
E = 30 106 psi
d =?
PL
AE
PL
200 lb(600 in.)
A=
=
= 0.008 in.2
LE 0.5 in. (30 106 psi)
L =
A=
d=
d 2
4
4A
4(0.008 in.2 )
=
= 0.101 in.
Solution 8.4
P = 35,000 lb
= 22,000 psi
P
A
P 35,000 lb
= 1.591 in.2
A= =
22,000 psi
A=
d=
d 2
4
4A
4(1.591 in.2 )
=
= 1.423 in.
Page 28 of 65

Solution 8.5
d o = 80 mm = 0.080 m
d i = 50 mm = 0.050 m
m = 60 MPa = 60 106 Pa
T =?
d 4 di 4
(0.080 m) 4 (0.050 m) 4
4
6
=
J = o
= 3.408 10 m
32
32
Tr
m =
J
m J 60 106 Pa (3.048 106 m 4 )
=
= 5.11 103 N-m
T=
r
0.040 m
Solution 8.6
d = 0.5 in.
L = 8 in.
T = 75 in.-lb
G = 12 106 psi
=?
d 4 (0.5 in.) 4
=
= 6.136 103 in.4
32
32
TL
75 in.-lb (8 in.)
=
=
= 0.0082 rad
JG 6.136 103 in.4 (12 106 psi)
J=
Solution 9.1
TF = 295 F
5
5
TC = (TF 32) = (295 32) = 146 C
9
9
TR = TF + 460 = 295 + 460 = 755 R
TK = TC + 273 = 146 + 273 = 419 K
Page 29 of 65

Solution 9.2
At Ti =70 F
Dhole = 2.000 in.
Dshaft = 2.002 in.
5
5
(TF 32 ) = (70 32 ) = 21.1 C
9
9
1
al = 25 106
C
Ti =
For a 0.001 in. clearance, the hole must enlarge to 2.003 in. (D = 0.003 in.).
D = DT
D
0.003 in.
= 60 C
=
D 25 106
( 2.000 in.)
C
60 C = T f Ti = T f 21.1 C
T =
T f = 60 C + 21.1 C = 81.1 C
Tf =
9
9
(TC ) + 32 = (81.1 C ) + 32 = 178 F
5
5
Page 30 of 65

Solution 9.3
Ti (iron ) = 1, 200 F
5
5
Ti (iron ) = (TF 32) = (1, 200 32) = 648.9 C
9
9
Ti (iron ) = TC + 273 = 648.9 + 273 = 921.9 K
Ti (water) = 55 F
5
5
Ti (water) = (TF 32) = (55 32) = 12.8 C
9
9
Ti (water) = TC + 273 = 12.8 + 273 = 285.8 K
T f (iron ) = T f (water) = ?
miron = 250 g = 0.250 kg
mwater = 2 kg
J
kg-K
J
c p (water) = 4,190
kg-K
Qiron = Qwater
c p (iron ) = 447
miron (c p (iron ) )(Tiron ) = mwater (c p ( water) )(Twater )
J
J
0.250 kg 447
(921.9 K T f ) = 2 kg 4,190
(T f 285.8 K)
kg-K
kg-K
103,022.3 111.75T f = 8,380T f 2,395,004.0

8, 491.8T f = 2, 498,026.3
T f = 294.17 K
T f = TK 273 = 294.17 273 = 21.17 C
9
9
T f = (TC ) + 32 = (21.17) + 32 = 70.1 F
5
5
Page 31 of 65

Solution 9.4
Win
Qout
Win = 5
Qout = 4
Q = U + W
U = Q W
U = 4 (5) = 1
The internal
engergy
increases
The internal
energy
increases.
Solution 9.5
Heat exchangers typically extract heat from a surface by means of convection as
described on page 73. In a typical forced-air home heating system, air passes over heating
elements or burner tubes to absorb the heat and warm the air.
Solution 10.1
Pabs = 14.7 psi
Pgage = 10 psi
Pabs = Patm + Pgage
Pabs = 14.7 psi 10 psi = 4.7 psi
Solution 10.2
w = tank width = 2 ft
l = tank length = 4 ft
h = tank height
Vtank = w l h = 2 ft 4 ft h = 250 gal
From Table 2-7:
0.1337 ft 3
3
250 gal
= 33.43 ft
1
gal
2 ft 4 ft h = 33.43 ft 3
h=
33.43 ft 3
= 4.2 ft
2 ft 4 ft
Page 32 of 65

Solution 10.3
A1 = 4 in.2
F1 = 1,000 lb
A2 = 0.250 in.2
F2 = ?
P1 =
F1
F
= P2 = 2
A1
A2
F1 F2
=
A1 A2
F2 =
A2 F1 0.250 in.2 (1,000 lb)

=
= 62.5 lb
4 in.2
A1
Solution 10.4
m
s
d1 = 500 mm = 0.5 m
v1 = 5
d 2 = 400 mm = 0.4 m
v2 = ?
A1v1 = A2 v2
d12
d 2
(v1 ) = 2 (v2 )
4
4
d12 (v1 ) = d 22 (v2 )
m
d 2 (v ) (0.5 m ) 5 s
m
v2 = 1 2 1 =
= 7.8
2
d2
s
(0.4 m )
2
Page 33 of 65

Solution 10.5
2
1
z1 = 0
z2 = 100 m
p1 = ?
p2 = 0
Assume v1 = v2
g = 9.81
m
s2
kg
m
N
9.81 2 = 9,810 3
m3
s
m
v22 p2
v2 p
+
+ z2 = 1 + 1 + z1
2g
2g
Since v1 = v2 the first terms on both sides of the equation cancel.
water = water g = 1,000
p2
p
+ z2 = 1 + z1
p1 p2
=
+ z2 z1
p1 = + 100 m 0
p1 = (100 m) = 9,810
N
N
(100 m) = 981,000 2 = 981 kPa
m3
m
Solution 11.1
From page 83, the three states of matter are gas, liquid, and solid.
Solution 11.2
From page 83, a liquid is a substance that has no definite shape, but does have definite
volume.
Page 34 of 65

Solution 11.3
From page 84, the two most important agencies that create and publish standards for
material testing are the American Society for Testing Materials (ASTM) and the
International Organization for Standardization (ISO).
Solution 11.4
From pages 84 and 86, a tensile test will reveal material properties such as proportional
limit, elastic limit, yield strength, ultimate tensile strength, breaking (rupture) strength,
ductility, and modulus of elasticity.
Solution 11.5
From page 87, the elastic limit is the point at which permanent deformation will begin as
the stress increases. It can also be defined as the minimum stress at which permanent
deformation occurs.
Solution 11.6
From pages 88 and 89, the modulus of elasticity is the ratio of stress to strain in the elastic
region.
Solution 11.7
From page 88, the two basic types of hardness tests are Brinell and Rockwell.
Solution 11.8
From page 89, an S-N chart provides fatigue properties of a material under test and the
number of stress cycles before failure.
Solution 12.1
From page 91, grain boundaries form when there are obstructions in orderly grain
growth.
Solution 12.2
From page 92, the addition of salt lowers the solidus temperature of water as shown in
Figure 12-4 for an alloy.
Solution 12.3
From page 93, the range of carbon content in typical steels is 0.0081%.
Solution 12.4
From Figure 12-7, the lowest possible austenitizing temperature is 1,341 F (727 C).
Page 35 of 65

Solution 12.5
From pages 96 and 97, oil is sometimes used in preference over water in quenching heattreated samples to avoid martensite formation. Oil cools at a slower rate than water.
Solution 12.6
H F = 80 BHN
H P = 380 BHN
%C = 0.5%
H =?
0.77 %C
%C
H = HF
+ HP
0.77
0.77
0.77 0.5
0.5
H = 80
+ 380
= 275 BHN
0.77
0.77
Solution 12.7
From Figure 12-10, the annealing temperature for a steel with 0.2% carbon is between
approximately 1,550 F and 1,600 F (843 C and 870 C ). The higher temperature,
1,600 F (870 C), would ensure the appropriate annealing temperature is used.
Solution 12.8
From Table 12-2, lead can be alloyed with steel to improve its machinability.
Solution 12.9
From page 103, martensitic stainless steel is typically used for making knives.
Solution 12.10
From page 103, nodular iron has excellent impact properties that would make it a logical
choice for the cast iron C-clamp.
Solution 12.11
From Table 12-5, 1XXX aluminum would be chosen when strength is not a consideration
but high electrical conductivity is a consideration.
Solution 12.12
From pages 99-101, normalizing is the only process on the list that is not used for surface
hardening. Normalizing is a softening process.
Page 36 of 65

Solution 13.1
From page 107, a small molecular chain is not a property of plastics.
Solution 13.2
From page 108, the two major types of polymerization reactions are addition
polymerization and condensation polymerization.
Solution 13.3
From page 109, the possible arrangements or mers in a copolymer are alternating, block,
random, and graft.
Solution 13.4
From Table 13-2, high-density polyethylene bears the recycling code number 2.
Solution 13.5
From page 107, organic molecules warrant the name polymers when they contain at least
100 mers.
Solution 13.6
From page 109, semi-crystalline plastics have higher mold shrinkage than amorphous
plastics.
Solution 13.7
From page 112, the chemical name for nylon is polyamide.
Solution 13.8
From page 113, hard thermoset plastics fall below the glass transition point. Polyester is a
hard thermoset. Therefore, it falls below the glass transition point.
Solution 14.1
From page 115, a composite is a combination of a reinforcing element and a resin binder
(matrix).
Solution 14.2
From page 116, advanced composites have a fiber-to-resin ratio greater than 50% by
weight.
Solution 14.3
From page 115, the fibers in advanced composites are usually made of carbon, aramid, or
boron.
Page 37 of 65

Solution 14.4
From page 116, the matrix holds the fibers in place and distributes the stress to the fibers.
Solution 14.5
From page 117, graphite fibers should be used rather than carbon fibers when greater
strength is required.
Solution 15.1
From page 120, the oldest carbide is tungsten carbide.
Solution 15.2
From page 119, refractory means able to withstand extremely high temperatures.
Solution 15.3
From page 119, ceramics typically exhibit ionic bonding.
Solution 15.4
From page 119, the purpose of adding soda and lime during the manufacture of glass is to
reduce the melting temperature, making the glass more fluid and retarding crystallization.
Solution 15.5
From page 121, CBN is the abbreviation for cubic boron nitride.
Solution 16.1
From page 127, auxiliary views show the true size and shape of features not parallel to
any principle view.
Solution 16.2
Solution 16.3
From page 129 and Figure 16-10, baseline dimensioning should be used to locate the top
surface of each step with edge 1-2.
Page 38 of 65
Solution 16.4
From page 130, an allowance is the difference in the diameters of the largest shaft and
the smallest hole as shown in Figure 16-12.
Allowance = smallest hole largest shaft
Allowance = 1.2 in. 1.1 in. = 0.1 in.
Solution 16.5
From page 131, the American National Standard system is based on holes.
Solution 16.6
From page 132, the basic shaft size is 50 mm with an IT grade of 6.
Solution 16.7
Unilateral tolerance
.505+.004
.000
Bilateral tolerance
.507 +.002
.002
Solution 16.8
Piston = 1.000 .001 in.
Allowance = 0.001 in.
Allowance = Smallest cylinder largest piston
0.001 in. = Smallest cylinder 1.001 in.
Smallest cylinder 1.002 in.
Piston 1.000+.001
.001
Cylinder 1.003+.001
.001
Page 39 of 65

Solution 16.9
1.002 0.2495 + 0.249 (1.004 X ) = 0

X = 0.0025
Solution 16.10
From Figure 16-17:
a is the average roughness
b is the waviness height
c is the lay
Solution 17.1
The MMC of a hole is the smallest diameter hole. In this case, the MMC is 0.620 in.
Solution 17.2
From Figure 17-2, geometric characteristic symbols provide specific control related to the
form, orientation, or outline of features; the relationship of features to an axis; or the
location of features.
Solution 17.3
From page 139, the symbols used in the feature control frame to modify the geometric
tolerance other than the implied condition are MMC and LMC.
Solution 17.4
From page 129, a basic dimension is a theoretically perfect dimension.
Page 40 of 65

Solution 17.5
From Figure 17-5, perfect form is required at MMC with surface straightness.
Solution 17.6
From Figure 17-5, perfect form is required at MMC with surface straightness. Therefore,
the size of the geometric tolerance zone is 0.000 in.
Solution 17.7
From page 139, flatness is the condition of a surface where all of the elements are in one
plane.
Solution 17.8
From page 142, circularity is controlled by a single cross-sectional tolerance zone defined
by two concentric circles.
Solution 17.9
From page 143, the perpendicularity tolerance zone is two parallel planes that are
perfectly 90 to a datum.
Solution 17.10
From page 144, total runout provides combined control of circularity, straightness,
coaxiality, angularity, taper, and profile when applied to a surface around a datum axis.
Solution 18.1
From page 153, IGES is used to exchange CAD data between different CAD systems.
Solution 18.2
From page 153, wireframe modeling is transparent in nature.
Solution 18.3
From page 154, constructive solid geometry (CSG) uses primitives to create solid images.
Solution 18.4
From page 154, solid modeling requires the most computer power.
Solution 18.5
From page 155, stereolithography (SLA) uses a laser and an ultraviolet-light-sensitive
polymer.
Page 41 of 65

Solution 18.6
From page 155, rapid prototyping can not create a part that can be physically tested.
Solution 19.1
From page 158, the three basic elements of the time-based strategy are organization of
process components and standardization, length of production run, and complexity of
scheduling procedures.
Solution 19.2
From page 159, it is least costly in the design stage to make product changes.
Solution 19.3
From page 159, the X in DFX stands for reliability, quality, testability, etc.
Solution 19.4
From equation 19-1:
De =
N min (tavg )
tact
Increasing the number of discrete fasteners will increase tact. Nmin and tavg will remain the
same. Therefore, the design efficiency (De) will decrease.
Solution 19.5
From page 160, the severity of the effect, likelihood of occurrence, and likelihood of
detection affect the RPN (risk priority number).
Solution 19.6
From page 162, the house of quality is used in the product planning stage of the QFD
process.
Solution 19.7
From page 165, the group technology methods for grouping parts into families are visual
inspection, production flow analysis (PFA), and classification and coding.
Solution 20.1
From page 172, a negative rake angle requires more cutting force.
Page 42 of 65

Solution 20.2
V = 300
ft
min
C = 420
n = 0.161
T =?
VT n = C
300T 0.161 = 420
420
= 1.4
300
ln T 0.161 = ln1.4
T 0.161 =
0.161ln T = ln1.4
ln1.4
= 2.09
0.161
= e 2.09
ln T =
eln T
T = 8.1 min
Solution 20.3
From page 172, crater wear occurs on the rake face of the tool.
Solution 20.4
From the choices given, high-speed steel will soften below 35 RC at 1,300 F according
to Figure 20-5.
Solution 20.5
From page 177, emulsified cutting oil uses a mixture of oil and water.
Solution 21.1
D = 1 in.
Vc = 100
ft
min
N =?
N=
ft
in.
Vc 12 100 min 12
ft = 382 rpm
=
1 in.
D
rev
Page 43 of 65

Solution 21.2
d =?
D = 3 in.
Pm = 3 hp
f r = 0.0052
in.
rev
ft
min
E = 80%
Vc = 100
U = 1 hp/in.3 /min
Q = 12 d f r Vc (The unit for f r in this equation is inches only.)
d=
Q
12 f r Vc
Ps
E
Ps = EPm = 0.80(3 hp) = 2.4 hp
Pm =
U=
Ps
Q
Q=
Ps
in.3
2.4 hp
4
2.
=
=
U 1 hp/in.3 /min
min
3
2.4 in.
Q
min
d=
=
= 0.385 in.
12 f r Vc 12 in. 0.0052 in. 100 ft
ft
min
Page 44 of 65

Solution 21.3
D = 0.5 in.
Vc = ?
N = 1,500 rpm
N=
Vc 12
D
N D
=
Vc =
12
0.5 in.
1,500 rpm
ft
rev
= 196
min
12 in.
ft
Solution 21.4
hps = ?
D = 1 in.
Vc = 300
ft
min
f r = 0.00078
in.
rev
E = 75%
U = 1 hp/in.3 /min
Ps
Q
Ps = U Q
U=
ft
in.
Vc 12 300 min 12 ft
=
= 1,146 rpm
1 in.
D
rev
in.3
Q = D 2 f r N = (1 in.) 2 0.00078 in. 1,146 rpm = 0.70

rev
4
4
min
N=
Ps = U Q = 1 hp/in.3 /min 0.70
in.3
= 0.70 hp
min
Page 45 of 65

Solution 21.5
ft = ?
D = 4 in.
n = 20 teeth
ft
min
in.
F =4
min
Vc = 300
F = ft n N
ft =
F
n N
N=
ft
in.
Vc 12 300 min 12
ft = 287 rpm
=
4 in.
D
rev
ft =
4 in.
F
in.
min
=
= 0.0007
20 teeth
n N
tooth
287 rpm
rev
Page 46 of 65

Solution 21.6
hpm = ?
w = 2 in.
D = 2 in.
n = 15 teeth
d = 0.250 in.
N = 120 rpm
in.
tooth
3
U = 1 hp/in. /min
f t = 0.00055
E = 75%
Pm =
Ps
E
Ps
Q
Ps = U Q
U=
Pm =
Ps U Q
=
E
E
Q = w d ft n N
Q = 2 in. 0.250 in. 0.00055 in.
tooth
15 teeth
rev
120 rpm = 0.495
in.3
min
3
in.3
U Q 1 hp/in. /min 0.495
min = 0.66 hp
Pm =
=
E
0.75
Solution 22.1
From page 193, cold forming produces strain hardening.
Solution 22.2
From Table 22-1, hot forming requires less force than warm forming.
Solution 22.3
From page 193, forward extrusion is another name for direct extrusion.
Page 47 of 65

Solution 22.4
From page 194, coining is a forging process that can create fine detail in both the top and
bottom surface of a part with only a small amount of deformation.
Solution 22.5
Do = 1 in.
D f = 0.750 in.
A=
D 2
4
% reduction in area =
Ao Af
Ao
100
(1 in.) 2 (0.750 in.) 2
4
4
% reduction in area =
100 = 43.8%
2
(1 in.)
4
Solution 23.1
T =?
D = 2 in.
2,000 lb
F = 50 ton
= 100,000 lb
1 ton
S = 35,000 psi
F = S DT
T=
F
100,000 lb
=
= 0.455 in.
S D
35,000 lb 2 ( )( 2 in.)
in.
Solution 23.2
c=?
a = 10%
t = 0.500 in.
c = at = 0.10(0.500 in.) = 0.050 in.
Solution 23.3
From page 201, nibbling punches out a series of overlapping holes to make a slot.
Solution 23.4
From page 201, flanging provides an accurate fastening surface.
Page 48 of 65

Solution 23.5
From page 204, the stripper prevents material being cut from sticking to the punch.
Solution 24.1
From page 207, the porosity of PM parts can be controlled, thus providing the ability to
make them less than 100% dense.
Solution 24.2
From page 206, lubricants are added to the powder to help the powder fill the die cavity
without air pockets.
Solution 24.3
From page 206, after compacting the powder, the part is called a green compact.
Solution 24.4
From page 207, sintering is the step in the PM process that fuses the metal particles
together after compaction.
Solution 24.5
From page 207, oil impregnation is the secondary operation used to make a bushing selflubricating.
Solution 25.1
From page 210, risers prevent shrinkage voids from occurring in the casting.
Solution 25.2
From page 210, cores are used to produce holes or internal cavities in castings.
Solution 25.3
From page 213, investment casting uses single-use wax patterns.
Solution 25.4
From page 213, cores are not used in evaporative casting to produce holes in the casting.
Solution 25.5
From page 213, die casting would be used to produce intricate, thin-walled aluminum
castings in large numbers.
Page 49 of 65

Solution 26.1
From page 217, a carburizing flame has too much acetylene and therefore contains excess
carbon.
Solution 26.2
From page 218, gas-metal-arc welding, also known as MIG welding or wire welding, is
an arc-welding process that uses a bare metal consumable electrode.
Solution 26.3
From page 218, SMAW is commonly referred to as stick welding or stick-electrode
welding.
Solution 26.4
From pages 221-222, brazing is performed at a higher temperature than soldering.
Solution 26.5
From page 221, ultrasonic welding relies on high-frequency vibrational energy.
Solution 26.6
From Table 26-1, water-based adhesives belong to the evaporative adhesive category.
Solution 27.1
From page 225, external mixing systems are most commonly used for production.
Solution 27.2
From page 225, in electrostatic spraying, the paint has the electrostatic charge.
Solution 27.3
From page 225, in electroplating, the part to be plated is the cathode.
Solution 28.1
From page 227, extruders are sized by their screw diameter and motor horsepower.
Solution 28.2
From page 230, the two major categories of blow molding are extrusion blow molding
and injection blow molding.
Solution 28.3
From page 230, the blank for blow molding is called a parison.
Page 50 of 65

Solution 28.4
From page 231, polystyrene is the standard material used for the measurement of the shot
size of injection molding machines.
Solution 28.5
From page 233, insufficient clamping for injection molding causes flash.
Solution 28.6
From page 233, in thermoforming, the plug assist reduces thinning of the plastic sheet.
Solution 29.1
From page 237, a prepreg is a partially cured composite with fibers aligned parallel to
each other.
Solution 29.2
From page 238, resin transfer molding resembles plastic injection molding.
Solution 29.3
From page 238, pultrusion resembles metal extrusion.
Solution 29.4
From page 238, roving is the term for a series of glass fibers gathered to form a bundle.
Solution 30.1
From page 241, two methods for producing glass plate are rolling and floating.
Solution 30.2
From page 241, tempered glass contains residual compressive stress to prevent it from
shattering.
Solution 30.3
From page 242, slip casting uses a suspension of clay in water.
Solution 30.4
From page 242, jiggering is a plastic forming process that uses a metal template and a
rotating plaster mold.
Solution 30.5
From page 243, glazing is used to make ceramic parts impermeable.
Page 51 of 65

Solution 31.1
From page 245, a double-sided printed circuit board contains circuit pathways on both
sides of the board.
Solution 31.2
From page 245, the insertion of axial-lead components is referred to as variable-centerdistance (VCD) insertion.
Solution 31.3
From page 247, solder bridges or icicles are wave-soldering defects that can cause short
circuits.
Solution 31.4
From page 248, reflow soldering is used with surface-mount devices.
Solution 31.5
From page 247, solder paste is applied to the circuit board by stencil printing when
surface-mount assembly is used.
Solution 32.1
From page 251, the manufacture-to-stock environment manufactures products in
anticipation of customer orders.
Solution 32.2
From page 252, the forecast for a shorter period of time will be more accurate than for a
longer period of time.
Solution 32.3
From page 253, the master production schedule converts the aggregate plan into a
separate plan for individual parts.
Solution 32.4
From page 254, the first-in/first-out (FIFO) priority method assumes the first job to enter
a work center is the first shop order to be worked on.
Solution 32.5
From page 255, MRP is time-phased planning.
Solution 32.6
From page 257, MRP II stands for manufacturing resource planning.
Page 52 of 65

Solution 33.1
From page 259, Toyotas production system also can be called lean production.
Solution 33.2
From page 261, kaizen is the Japanese term for ongoing improvement involving everyone
managers and workers.
Solution 33.3
From page 261, one-piece flow is being used when the introduction of one unit is
balanced by the completion of another unit of finished product.
Solution 33.4
From page 260, Takt time is the available work time per shift divided by the customer
demand rate per shift.
Solution 33.5
From page 263, a pull system does not allow parts to be produced until authorization is
received from the subsequent operation.
Solution 33.6
From pages 261 and 263, kanban is the Japanese term for the signal used to trigger the
production of components in JIT manufacturing.
Solution 34.1
From page 266, special-purpose machines can provide faster production rates and high
quality for some parts.
Solution 34.2
From page 266, a good fixture must confine a part through six degrees of freedom.
Solution 34.3
From page 267, synchronous assembly is performed when all the workpieces move at the
same time.
Solution 34.4
From page 268, the product-process (cellular) layout produces one part family in a given
cell.
Page 53 of 65

Solution 34.5
From page 270, preventive maintenance advocates replacement of machine components
at specified time intervals.
Solution 34.6
N t = 15 sec
At = 20 sec
Pr = ?
At Pr
100
100 N t 100 15 sec
Pr =
=
= 75%
At
20 sec
Nt =
Solution 34.7
N t = 10 sec
Pa = 10%
St = ?
St =
N t (100 + Pa ) 10 sec (100 + 10)

=
= 11 sec
100
100
Solution 35.1
From page 274, dependent demands are derived from the demand for other items.
Solution 35.2
From page 274, the principle measure related to balancing the cost of carrying inventory
with the service level required is known as inventory turns.
Solution 35.3
A = 100,000 units
S = $50
c = $10
i = 20%
EOQ = ?
EOQ =
2 AS
2(100,000)(50)
=
= 2, 236
ic
0.20(10)
Page 54 of 65

Solution 35.4
From page 275, ABC inventory analysis categorizes items based on their annual usage
measured in dollars.
Solution 35.5
From page 276, to achieve zero inventory (not near-zero), the maximum acceptable
defect rate from suppliers is zero.
Solution 35.6
From page 276, money from customer rebates flows from left to right in the supply chain.
Solution 36.1
From page 281, justification for purchasing and installing automation includes to improve
product quality, improve productivity, improve work environment quality, or improve
development time.
Solution 36.2
From page 281, CIM is the integration of design, engineering, manufacturing, and
business functions.
Solution 36.3
From page 281, MEI stands for manufacturing enterprise integration.
Solution 36.4
From Figure 36-1, the customer is represented by level one of the MEI wheel.
Solution 37.1
From page 285, bandwidth is the term used to describe the number of signals that can be
carried simultaneously on the same conductor.
Solution 37.2
From page 286, the client server provides real-time access to database and CAD files.
Solution 37.3
From page 286, fiberoptic cabling is least sensitive to electromagnetic radiation.
Page 55 of 65

Solution 37.4
From page 289, bridges allow two similar but different networks to communicate with
each other.
Solution 37.5
From Figure 37-2, the star topology uses a central hub that each computer is connected
to.
Solution 37.6
From page 291, hypertext transfer protocol (HTTP) is the protocol used to transfer
information from a web server to a web browser.
Solution 38.1
From page 381, M03 starts the spindle clockwise.
Solution 38.2
From page 294, automatic programming of tools (APT) is popular for performing four- or
five-axes CNC operations.
Solution 38.3
From page 293, the spindle of a three-axis or two-axis CNC machine is generally
designated as the Z-axis.
Solution 38.4
From page 298, open-loop control contains no feedback.
Solution 38.5
From page 297, resolvers are less sensitive to vibration and temperature changes.
Solution 38.6
Using the G-codes and M-function from 380 and 381, respectively, the milling program
will generate the letter X. The program assumes that Z0 is the surface of the part.
Solution 39.1
From page 301, PLCs were designed to replace relays.
Solution 39.2
From page 301, PLCs without data communication result in islands of automation.
Page 56 of 65

Solution 39.3
From page 303, PLCs are sized by the number of I/O (inputs and outputs).
Solution 39.4
From page 303, relay ladder logic has historically been the programming language for
PLCs.
Solution 39.5
From Figure Q39-1, if all the inputs are off (low), output D will be off since either of the
three branches will turn on output D. For output D to be on, input A or B must be on
(high) and C must be off (low).
Solution 40.1
From page 305, the hydraulic power system is typically used for heavy loads.
Solution 40.2
From page 306, the robotic joints of motion are called degrees of freedom.
Solution 40.3
From page 306, adaptive control requires outside sensing to modify the robot program.
Solution 40.4
From page 306, the tool coordinate system has its center on the tool flange.
Solution 40.5
From Figure 40-4, the shape of the work envelope created by a polar-arm robot is
spherical.
Solution 41.1
From page 309, triangulation is used to determine the exact location of an AGV.
Solution 41.2
From page 309, an AS/RS system produces a smaller footprint than that of conventional
storage.
Solution 41.3
From page 310, the density of a bar code is defined by the width of the narrowest bar.
Page 57 of 65

Solution 41.4
From page 311, radio frequency identification uses a transponder attached to a pallet or
part.
Solution 41.5
From pages 311 and 312, a machine vision system forms an image of the part.
Solution 42.1
From page 315, QC is reactive in responding to defects and QA is proactive in its
approach to defect prevention and reliability.
Solution 42.2
From page 315, TQM is driven by customer needs.
Solution 42.3
From page 316, final inspection is an appraisal cost.
Solution 42.4
From page 317, the primary function of ISO standards is to facilitate international trade.
Solution 42.5
From page 317, if a company is ISO 9000 certified that does not guarantee that all the
parts they produce are good.
Solution 42.6
From page 317, U.S. Congress created the Malcolm Baldrige Award.
Solution 42.7
From page 317, customer focus and satisfaction are the Baldrige Award criteria
emphasized the most.
Solution 43.1
From page 320, excessive tool wear produces assignable variability.
Solution 43.2
From page 321, two measures of dispersion are standard deviation and range.
Page 58 of 65

Solution 43.3
x = 1.875 in.
= 0.0005 in.
n = 1,000
Parts < 1.8745 in. = ?
Parts < 1.8745 in. = x
= 68.26%
68.26%
= 34.13%
2
The percentage of parts smaller than x = 50 %
x = 50% 34.13% = 15.87%

15.87% (1,000 parts) = 158.7 159 parts
Page 59 of 65

Solution 43.4
Subgroup
1
2
3
4
5
6
7
8
9
10
11
12
13
x2
22.5
22.5
20.5
22.0
19.5
23.5
22.0
20.5
22.5
23.0
19.5
21.0
20.5
x1
22.0
20.5
20.0
21.0
22.5
23.0
19.0
21.5
21.5
21.5
20.0
19.0
19.5
x=
xi 278.125
=
= 21.39
N
13
R=
Ri 29.5
=
= 2.27
N
13
x3
22.5
22.5
23.0
22.0
22.5
21.0
22.0
19.0
20.0
22.0
21.0
21.0
21.0
x4
24.0
23.0
22.0
23.0
22.0
22.0
20.5
19.5
22.0
23.0
20.0
21.0
20.5
SUM
x
22.750
22.125
21.375
22.000
21.625
22.375
20.875
20.125
21.500
22.375
20.125
20.500
20.375
278.125
R
2.0
2.5
3.0
2.0
3.0
2.5
3.0
2.5
2.5
1.5
1.5
2.0
1.5
29.5
From Table 43-4 with a subgroup size of 4:

A2 = 0.729
D4 = 2.282
D3 = 0
UCLX = x + A2 R = 21.39 + 0.729(2.27) = 23.05
LCLX = x A2 R = 21.39 0.729(2.27) = 19.74
UCLR = D4 R = 2.282(2.27) = 5.18
LCLR = D3 R = 0(2.27) = 0
Page 60 of 65

Solution 43.5
USL = 23.0
LSL = 19.0
USL LSL
6
R
=
d2
Cp =
From Table 43-3 for a subgroup size of 4:

d 2 = 2.059
=
R
2.27
=
= 1.10
d 2 2.059
Cp =
USL LSL 23.0 19.0

=
= 0.61 < 1.33
6
6(1.10)
From page 328, C p < 1.33 means the process is incapable.

Solution 43.6
nearest specification x
3
23.0 21.39
C pk =
= 0.488
3(1.10)
The answer is slightly different than the answer given on page 388 due to rounding.
C pk =
Solution 44.1
From page 331, repeatability is a test of precision.
Solution 44.2
From page 332, calibration is the process of comparing a measuring device against a
higher-order standard of greater accuracy.
Solution 44.3
From page 332, rules and micrometers are absolute measurement instruments.
Solution 44.4
From Figure Q44-1, the diameter being measured is larger than 0.075 and less than 0.100.
The diameter is, therefore, 0.075 plus the thimble value or 0.006, which equals 0.081 in.
Page 61 of 65

Solution 44.5
From page 336, CMM stands for coordinate measuring machine.
Solution 44.6
From page 337, technique error occurs when an operator uses the correct measurement
instrument but the wrong measuring procedure.
Solution 44.7
When designing a go/no-go gage for a shaft, the go side must be able to fit over the
largest shaft that meets specifications (2.150). Using a gage tolerance of 10% and wear
allowance of 5%:
Total tolerance = upper limit lower limit = 0.000 0.002 = 0.002
gage tolerance = 0.1 0.002 = 0.0002
wear allowance = 0.05 0.002 = 0.0001
The go side has a gage tolerance of 0.0002 applied unilaterally on the negative side.
Since the go side is subject to the most wear, its diameter is decreased by 0.0001.
The no-go side should not be able to fit over any shaft within specifications. The no-go
side has a gage tolerance of 0.0002 applied unilaterally on the positive side. Since the nogo side is not designed to fit over the shaft, the wear allowance is not used.
Final gage dimensions:
Go: 2.1499+.0000
.0002
No-Go: 2.1480+.0002
.0000
Solution 44.8
Using Table 44-1, the gage tolerance for a Class Z gage is 0.00020. The go side must be
inserted into the smallest hole (3.000). The go side has a gage tolerance of 0.00020
applied unilaterally on the positive side. The problem does not include a wear allowance.
The no-go side must not be able to be inserted into any hole within specifications. The
no-go diameter is 3.004 with a gage tolerance of 0.00020 applied unilaterally on the
negative side.
Final gage dimensions
Go: 3.0000+.0002
.0000
No-Go: 3.0040+.0000
.0002
Page 62 of 65
Solution 45.1
From page 345, a person retains 20% of what is heard.
Solution 45.2
From page 350, the management concept in which many of the decisions affecting the
operation of the plant are made at the lower levels is called decentralization.
Solution 45.3
From page 351 and Figure 45-6, a Gantt chart graphically depicts the progress of various
tasks with shaded horizontal bars.
Solution 45.4
From page 352, Pareto analysis is a problem-solving tool that identifies the vital few and
the trivial many.
Solution 45.5
From page 354, participatory management views workers as important assets of the
organization.
Solution 45.6
From page 354, management by objectives is an example of the goal-setting theory.
Solution 46.1
From page 358, an employee who participates in an unlawful union-organized strike may
be discharged and not be entitled to reinstatement when the strike ends.
Solution 46.2
From page 360 and the choices given, employee "right-to-know" laws focus on
hazardous materials.
Solution 46.3
From Table 46-1, the minimum standing height for a walk-in freezer would be the stature
of the 95th percentile male at 74.4 in. (1,890 mm).
Solution 46.4
From Table 46-3, the maximum sound level that employees can be exposed to during an
8-hour period without hearing protection is 90 dBA.
Page 63 of 65
Solution 46.5
From page 364, a truck seat that resonates at 5 Hz could cause resonance of the internal
organs of the passengers.
Solution 46.6
From page 364-365, repeatedly using a screwdriver throughout the workday could cause
a cumulative trauma disorder such as carpal tunnel syndrome.
Solution 47.1
F = 50,000
n = 20
i = 6%
P=?
P = F ( P/F , i, n)
( P/F , i, n) =
1
1
=
= 0.3118
n
(1 + i )
(1 + 0.06) 20
P = 50,000(0.3118) = $15,590
Solution 47.2
P = 15,000 4,000 = 11,000
i=
12% 1 year
1%
=
year 12 months month
12 months
n = 3 years
= 36 months
year
A=?
A = P ( A /P, i , n)
( A /P, i , n) =
i (1 + i ) n
0.01(1 + 0.01)36
=
= 0.0332
(1 + i ) n 1 (1 + 0.01)36 1
A = 11,000(0.0332) = $365
Page 64 of 65

Solution 47.3
Option 1
Option 2
P = 46,000
P = 46,000
n = 5 years
n = 7 years
i = 9%
A = 4,000
i = 9%
EUAC1 = P ( A/P, i, n)
( A /P, i , n) =
i (1 + i ) n
0.09(1 + 0.09)5
=
= 0.2571
(1 + i ) n 1 (1 + 0.09)5 1
EUAC1 = 46,000(0.2571) = $11,827
EUAC2 = P ( A/P, i, n) + 4,000

( A /P, i , n) =
i (1 + i ) n
0.09(1 + 0.09)7
= 0.1987
=
(1 + i ) n 1 (1 + 0.09)7 1
EUAC2 = 46,000(0.1987) + 4,000 = $13,140

The annualized cost of the second option ($4,000 service contract) is more expensive.
It is not a sound economic decision.
Solution 47.4
From page 370, storing work-in-process parts is a variable cost since space and carrying
costs change with the amount of work-in-process parts.
Solution 47.5
From page 372, inspection does not add value to a product. It does not add function or
esteem value to a product.
Page 65 of 65
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Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

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0.83 + 0.76 + 0.79 + x = 3.20

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Volumebox = length width height = 256 in.3

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Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

2 + 2(1) 3 + 2(2) 1 + 2(1) 1 + 2(5)

1(1) + 1 1(2) + 3 1(1) + 2 1(5) + 2

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Convert the matrix back into equation form.

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

2 possible red sevens 2

1 possible seven of spades 1

12 possible face cards 12 3

Copyright 2002 Society of Manufacturing Engineers

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6 ways to make a seven 6 1

1 way to make a two 35

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1(35) + 3(45) + 6(55) + 8(65) + 10(75) + 4(85) + 2(95)

= 1(352 ) + 3(452 ) + 6(552 ) + 8(652 ) + 10(752 ) + 4(852 ) + 2(952 ) = 162, 450

162, 450 34(67.652 )

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

I = 108 1012 2 = 104 2

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

I = 109 1012 2 = 103 2

miles 63,360 in.

rev 1 min 5 slots or cycles

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Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

Fundamentals of Manufacturing Solutions Manual

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Fundamentals of Manufacturing Solutions Manual

Copyright 2002 Society of Manufacturing Engineers

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