The machine shop at the Pogi Space Laboratories received an order from their engineering department for 100 of the vented cap screws shown in Figure CS-30. The machine shop foreman returned the order, stating that there was no practical way to make these other than by hand. The design engineer insisted that the vent slot, as designed, was essential to assure no pressure buildup around the threads of the screw body in the intended application, and that he knew they could be made because he had seen such cap screws.
To accommodate the shop, however, the design engineer redesigned the part, now specifying that a vent hole be drilled parallel to the axis of the cap at location D. The small hole, with cross-sectional area equal to the previous 0.062 in. × 0.031 in. slot, would be drilled 1 in. deep through the cap to connect to the longitudinal slot. This would eliminate the right-angle slot geometry.
1. What do you think of this solution? What problems will be incurred in the manufacture of the vented cap screw?
2. As the manufacturing engineer, working with the design engineer, can you suggest an alternative redesign that would make a slot practical to manufacture? Show a sketch of your redesigned cap screw.

Tolerance on slot 0.002 0.062 0.062 0.0631 Threaded 416 UNFx 2 cap screw (Dimensions in inches)