Larry Cornelius and Marcelo Veras are consulting engineers and have just received the drawing shown in Figure CS-23. This is one of four legs on a casting made by the the Lorac Warpug Company. These legs are used to attach the device to the floor. The section drawing to the right shows the typical loading to which the leg is subjected. The company is currently drilling the bolt hole and then counterboring the land, but manufacturing has experienced some difficulty in machining the four holes. They report a lot of drill breakage. Quality control reports that distances between the four holes are frequently too large. Sales has recently reported that a substantial number of in-service failures have occurred with these
legs. Larry and Marcelo have obtained a sketch from sales showing where the legs typically fail. This casting is manufactured from gray cast iron using the sand casting process.
1. What machining difficulties should Larry and Marcelo suspect this leg to have?
2. Why were the distances between the holes too large?
3. What should Larry and Marcelo recommend for solving these problems in the future in terms of materials, design, and manufacturing methods?
4. What should Larry and Marcelo recommend be done with the units in the field to stop the failures?
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