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Which consequence follows from failing to undercut the mica?

  • A.The commutator wears rapidly, which reduces its diameter and therefore shortens the life of the armature
  • B.Nothing
  • C.The segments short together, which occurs because the copper is smeared across the insulation during machining
  • D.The brushes ride on the insulation and lose contact

Answer: D

Mica is harder than copper, so it stands proud as the copper wears and lifts the brushes, which arcs and destroys the commutator. Copper smearing across the mica is a genuine machining fault too, which makes the last option a real concern. Naming the cost of a choice alongside its benefit is what turns a fact into a design decision. The order in which the effects act is what decides the outcome, so it is worth establishing first.

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