Fundamentos de manufactura philip rufe 2 ed

From page 27, it can be inferred that if the millimeter is used as the standard of length formost drafting operations, it would be commonly used for machining practices.... From page 84,

No liability is assumed by the publisher with respect to use of information contained herein While every precautionhas been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions.Publication of any data in this book does not constitute a recommendation or endorsement of any patent, proprietaryright, or product that may be involved.

Additional copies may be obtained by contacting:

Society of Manufacturing Engineers

SME staff who participated in producing this book:

Philip Mitchell, Senior Editor

Rosemary Csizmadia, Production Supervisor

Kathye Quirk, Graphic Designer/Cover Design

Frances Kania, Administrative Coordinator

Printed in the United States of America

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 view questions, the manual directs readers to the location in the book where the answer can be found.

Solution 1.5

2 4 ft

46 ft2(2 4 ft) 2 46 ft

4th test grade0.83 0.76 0.79

0.804

0.83 0.76 0.79

40.83 0.76 0.79 3.203.20 0.83 0.76 0.790.82 82%

x x

x

2 2

5 5 4(1)(5)2(1)1.382, 3.618

b c x x

2 2

2(1)3.193, 2.193

b c g g

2 2

19 19 4(6)( 7)2(6)

b c r r

[ ] [ ]chips

2 2

b c x x

3 box

2 2 2

2

2

Volume = length × width × height = 256 in

( 4)( 4 4)(2) 256( 4)( 8)(2) 256

12 32 2 256

2 24 64 256

2 24 192 0

42224192( 24) ( 24) 4(2)( 192)

17.49 in

2(2)17.49 in

b c l

4(3 2 5)3( 4 5 5)

12 15 15

7 355

3 2(5) 5

3 155

x x x

Solution 1.14

2 + = 5

2 + 3 + = 1 + 3 + 2 = 2Convert the equations into an augmented matrix

Convert the matrix back into equation form.

+ 3 + 2 = 2

5 + = 3

16 = 52

52 13 =

x x

25 125log 25 log125log 25 log125log125log 251.5

2 10

10 2 10 3 log

5 2 2

2

3

23

23

2

3100,0002

2(100,000)3200,0003258.2

x x x

x

x x x

2 cylinder

10 m

10 m( )( ) (10 m)(10 m) 314.2 m( ) (5 m) 78.5 m

314.2 m 78.5 m 392.7 m

1 LPaint needed (392.7 m ) 78.5 L

46

4

3 45

c c

4

3

c

2 coscos

A

bc A

B

ac B

2 2 2

60

?68

2 cos

6 8 2(6)(8) cos 607.2

a a

4 possible sevens 4 1a) P(seven)

a B C

Permutations of the numbers 1 through 6 taking two at a time:

Therefore, the possible outcomes of rolling dice = 30 + 6 = 36

6 ways to make a seven 6 1a) P(seven) =

Getting a head with the first coin does not affect the outcome of the other coin

Therefore, they are independent events

1 1 1P(H and H) =

2 2 4

1 1 1P(T and T) =

2 2 4Getting two heads and two tails wit

4 4 2

2

5 )14.2

0.504 0.497

1.750.004

3( ) 2(12 ) 3 24

3 ( 8)

0 when 0,8

2(3 ) 1(24 ) 6 24(0) 6(0) 24 24

(8) 6(8) 24 24

Local maximum at 0Local minium at 8

x x

14

a b

x

n c

From page 27, it can be inferred that if the millimeter is used as the standard of length formost drafting operations, it would be commonly used for machining practices.

From Figure 3-1, at 880 nanometers, the light is not in the visible spectrum.

6

9 6

14 –9

From Figure 3-2, the eye is more sensitive to green than blue Therefore, green would be

a better choice for safety

1 1

7 m

8 m41.19tan 41.19

1 1( water ) 2(air )

2 1

2

3

301.331sin sin1.33sin 30 1sin

3 m

1.73 mtan 60

3 m 1.73 m 1.27 mtan 48.32

1.27 m1.27 m (tan 48.32 ) 1.4

12 2

0

12

12 2

12 2

log W 10

8 12 2

?

80 dB 10 log

W10m

W10mW

I I

2 12

6 2 12 2

Relative intensity 10log

W

4 10

mW10m

W

4 10

mRelative intensity 10log 66 dB

W10m

I

12 2

0

12

12 2

12 2

log W 10

9 12 2

90 dB 10 log

W10m

W10mW

2

W

10 mW

10 2 m 4 m 8 10 Wm

P I V

V I R V R I

Pa R

beam beam

[ sin 30(5 ft)] [500 lb(5 ft)] 0

500 lb (5 ft)sin 30

5 ft

500 lb

1,000 lbsin 30

Two forces of equal magnitude and opposite sense with parallel lines of action form acouple as illustrated in Figure 6-7

100 N sin 45(2 m) 141.4 N-mThe moment must be clockwise to keep the beam in equilibrium

=

M

down the plane = 100 lb sin 30 50 lbFriction 0.25

100 lb cos 30 0

100 lb cos 30 86.6 lb0.25(86.6 lb) 21.7 lbWeight down the plane (50 lb) > friction force (21.7 lb)Block will slide down the p

0.3( ) 346.8 N490.5 N cos 45 0490.5 N cos 45 346.8 N0.3(346.8 N) 346.8

2

0 2 2

2 2

2

2

m

30 sm

5 s0

?2

10 s

0 (velocity at particle’s maximum height)m

9.81 s

9.81 sTotal travel time = 2t = 2 5.1 s 10.2 s

t

t

( )

2

0

2 0

2 2

rad

6 s

10 s0

?

2rad

1 sft

10 s

0 0

v r

t

1.5 ft

32.2 s

ft 1 min ft

300 5 min 60 s s

12

W x

2

2

2,000 lb0.750 in

42,000 lb

4,527 psi(0.750 in.)

4

=

=π

=

π

P d d A P A

236,000 psi

36,000 psi

18,000 psi2

=

σ

=σ

y a s

PL L AE PL A LE d A A d

J Tr J J T r

d J TL JG

( ) ( )

hole shaft

6 al

At =70 F 2.000 in

i

T D D

D

D T D

(iron )

(iron )

(iron ) ( water )

4 ( 5) 1The internal engergy increases

tank width 2 ft tank length 4 ft tank height

h h

W in

Q out

The internal energy increases

2 1

1

2 2

1 1

2

m5s

7.8s0.4 m

1 2 1 2

m9.81 s

From page 84, the two most important agencies that create and publish standards formaterial testing are the American Society for Testing Materials (ASTM) and theInternational Organization for Standardization (ISO).

From pages 84 and 86, a tensile test will reveal material properties such as proportionallimit, elastic limit, yield strength, ultimate tensile strength, breaking (rupture) strength,ductility, and modulus of elasticity

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 permanentdeformation occurs

From page 89, an S-N chart provides fatigue properties of a material under test and the

number of stress cycles before failure

From pages 96 and 97, oil is sometimes used in preference over water in quenching treated samples to avoid martensite formation Oil cools at a slower rate than water.

From page 107, a small molecular chain is not a property of plastics.

From page 108, the two major types of polymerization reactions are addition

polymerization and condensation polymerization.

From page 116, the matrix holds the fibers in place and distributes the stress to the fibers.

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 shaftAllowance = 1.2 in – 1.1 in = 0.1 in

Unilateral tolerance 505Bilateral tolerance .507

+

− +

Piston 1.000Cylinder 1.003

+

− +

−

( )

1.002 0.2495 0.249 1.004 00.0025

=

X X

From Figure 16-17:

• a is the average roughness

• b is the waviness height

From Figure 17-5, perfect form is required at MMC with surface straightness.

From page 142, circularity is controlled by a single cross-sectional tolerance zone defined

by two concentric circles

From page 155, rapid prototyping can not create a part that can be physically tested.

From page 158, the three basic elements of the time-based strategy are organization ofprocess components and standardization, length of production run, and complexity ofscheduling procedures

Increasing the number of discrete fasteners will increase t act N min and t avg will remain the

same Therefore, the design efficiency (D e) will decrease

4201.4300

ln ln1.40.161ln ln1.4ln1.4

0.1618.1 min

T T T T T

D

min80%

0.5 in.

?1,500 rpm12

0.5 in

1,500 rpm

ftrev

196in

0.00078

rev75%

P U Q

V N

( )

?

4 in

20 teethft300minin

4min

F f

n N

V N

D

F f

n N

s

s m

t

m

hp w D n d N f U E

P P E

P U Q

3

1 hp/in /min 0.495 min

0.66 hp0.75

×

Q E

From page 194, coining is a forging process that can create fine detail in both the top andbottom surface of a part with only a small amount of deformation.

=

=π

F T

S D

?10%

From page 204, the stripper prevents material being cut from sticking to the punch.

From page 217, a carburizing flame has too much acetylene and therefore contains excesscarbon.

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

From page 231, polystyrene is the standard material used for the measurement of the shotsize of injection molding machines.

From page 242, jiggering is a plastic forming process that uses a metal template and a

rotating plaster mold

From page 245, a double-sided printed circuit board contains circuit pathways on bothsides of the board.

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

From page 259, Toyota’s production system also can be called lean production.

From page 261, kaizen is the Japanese term for ongoing improvement involving everyone

—managers and workers

From page 261, one-piece flow is being used when the introduction of one unit isbalanced by the completion of another unit of finished product

From page 260, Takt time is the available work time per shift divided by the customer

demand rate per shift

From page 263, a pull system does not allow parts to be produced until authorization isreceived from the subsequent operation

From pages 261 and 263, kanban is the Japanese term for the signal used to trigger the

production of components in JIT manufacturing

From page 270, preventive maintenance advocates replacement of machine components

at specified time intervals

t r

t

N A P

N

N P

A

10 sec10%

?(100 ) 10 sec (100 10)

?

2 2(100,000)(50)

2, 2360.20(10)

AS EOQ

ic

From page 275, ABC inventory analysis categorizes items based on their annual usagemeasured in dollars.

From page 285, bandwidth is the term used to describe the number of signals that can be

carried simultaneously on the same conductor

From page 289, bridges allow two similar but different networks to communicate witheach other.

From page 293, the spindle of a three-axis or two-axis CNC machine is generally

designated as the Z-axis.

From page 303, PLCs are sized by the number of I/O (inputs and outputs).

From page 311, radio frequency identification uses a transponder attached to a pallet orpart.

1.875 in.

0.0005 in

1,000Parts < 1.8745 in = ?Parts < 1.8745 in = 68.26%

68.26%

34.13%

2The percentage of parts smaller than = 50 %50% 34.13% 15.87%

rts

From Table 43-4 with a subgroup size of 4:

0.7292.2820

21.39 0.729(2.27) 23.0521.39 0.729(2.27) 19.742.282(2.27) 5.18

A D D

LCL D R3 =0(2.27)=0

2

2

23.019.0ˆ6ˆ

From Table 43-3 for a subgroup size of 4:

2.0592.27

2.059

23.0 19.0

0.61 1.33ˆ

C R d

d R d

0.4883(1.10)

The answer is slightly different than the answer given on page 388 due to rounding

From page 336, CMM stands for coordinate measuring machine.

Total tolerance = upper limit – lower limit = 0.000 – 0.002 = 0.002

gage tolerance = 0.1 × 0.002 = 0.0002wear allowance = 0.05 × 0.002 = 0.0001The 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-goside has a gage tolerance of 0.0002 applied unilaterally on the positive side Since the no-

go side is not designed to fit over the shaft, the wear allowance is not used

Final gage dimensions:

.0000 0002

.0002 0000

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 0.00020applied 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 Theno-go diameter is 3.004 with a gage tolerance of 0.00020 applied unilaterally on thenegative side

Final gage dimensions

.0002 0000

.0000 0002

From page 345, a person retains 20% of what is heard.

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

From page 360 and the choices given, employee "right-to-know" laws focus onhazardous materials

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)

From Table 46-3, the maximum sound level that employees can be exposed to during an8-hour period without hearing protection is 90 dBA

Solution 46.5

From page 364, a truck seat that resonates at 5 Hz could cause resonance of the internalorgans of the passengers

From page 364-365, repeatedly using a screwdriver throughout the workday could cause

a cumulative trauma disorder such as carpal tunnel syndrome

20

50,000206%

P F i n

i P

36 36

n A

A P i n

i A

Option 1 Option 246,000 46,000

5 years 7 years9% 4,000

1

2

9%

( / , , )(1 ) 0.09(1 0.09)

(1 ) 1 (1 0.09) 146,000(0.2571) $11,827

( / , , ) 4,000(1 ) 0.09(1( / , , )

2

0.09)

0.1987(1 0.09) 1

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

Published by the Society of Manufacturing Engineers, 2001, Edited by Philip Rufe, CMfgE

pp 400 (est.), 237 figures, 47 tables,

256 equations, ISBN: 0-87263-52-44

$75 [SME Member: $63}

Request Order Code: PI-2942-4475

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This book covers the full spectrum of rudimentary

9 Parts, 45 Chapters Include Mathematics •

Physics • Materials (Metals, Plastics, Composites, Ceramics) •

Product Design (Engineering Drawing, GD&T, Computer-Aided Design,

Tools) • Manufacturing Processes (Cutting Tool Technology,

Machin-ing, FormMachin-ing, CastMachin-ing, etc.) • Production Systems (Traditional

Plan-ning and Control, Lean Production, Process Engineering, Inventory

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Because it contains the essentials, Fundamentals of Manufacturing, Second

Edition is a “must-have” for:

• Veteran manufacturing engineers who need to upgrade

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• Non-engineers who need to talk intelligently about

manufacturing engineering and technology on their job

Features

• Thorough review of manufacturing fundamentals with samples

and practice problems

• Detailed table of contents and index

• Referencing feature provides quick access to figures, tables,

equations, problems, and solutions

• Equations, newly reformatted, are arranged logically according the

sequence they’re presented

• Includes a number key to practice problems

• Up-to-date with current theoretical models, notably lean

manufacturing

Benefits

• Specific information is easy to find

• “User-friendly” presentation and layout makes for good retention and

enjoyable reading

• You learn about real-life manufacturing situations through

example problems in each chapter

• SME’s Fundamental Manufacturing Processes® videotapes naturally

tie-in (see back)

It is “official” information. Fundamentals of

Manufac-turing is based on the “body of knowledge” which the ManufacManufac-turing

Engineering Certification Institute has deemed mandatory for all

manufacturing engineers and technologists to know

Fifteen manufacturing experts, which includes educators, practitioners

in the field, subject matter specialists, have checked the content for

relevancy, accuracy and clarity, guaranteeing focused self-study and

solid answers to questions regarding the fundamentals It’s arguably

the most well-grounded and comprehensive textbook of its kind

Official “Recommended Study Guide”

Certification Institute

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