Weight reduction holes in aluminum tubing

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SUMMARY

The discussion focuses on reducing the weight of a 36-inch long, 1-inch square, and 1/16-inch thick aluminum tube for use in a radio-controlled airplane. A recommended alternative is to replace the aluminum tube with a graphite spar, which offers superior strength-to-weight ratio. If holes are to be drilled in the aluminum tube, it is advised to place them on the sides where bending stresses are minimized, with a maximum hole diameter of 0.5 inches, avoiding any holes in the top or bottom of the tube.

PREREQUISITES
  • Understanding of material properties, specifically aluminum and graphite
  • Knowledge of structural engineering principles related to bending stresses
  • Familiarity with radio-controlled airplane design and weight considerations
  • Basic machining skills for drilling and modifying materials
NEXT STEPS
  • Research the properties and applications of graphite spars in aerospace design
  • Learn about stress distribution in beams and how to calculate bending stresses
  • Explore techniques for weight reduction in structural components
  • Investigate best practices for drilling holes in aluminum without compromising structural integrity
USEFUL FOR

This discussion is beneficial for aerospace engineers, hobbyists designing radio-controlled airplanes, and anyone interested in optimizing the weight and strength of structural components in lightweight applications.

Kansasman
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I want to reduce the weight of a square aluminum tube, 36 inches long, 1 inch square, and 1/16 inch thick, while maintaining as much strength as possible. The tube will be used at the body of a radio-controlled airplane. Where should the holes be (what part of the tube), how big, and what spacing? Thanks in advance.
 
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I would first of all recommend replacing the aluminum tube with a graphite spar, which would be much lighter and at the same time stronger. With that being said, you could try removing some material from the middle of the "sides" of the aluminum beam where the bending stresses would be the least, but I wouldn't drill holes bigger than .5" in it, and no holes in the top or bottom.
 

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