What would be the flat layout dimension of a U-shaped channel 1" x 5" x 1" made of .064 thick 2024-T6 aluminum using minimum bend radius?

To determine the flat layout dimension of a U-shaped channel made of .064 thick 2024-T6 aluminum, we start with the dimensions of the channel, which are 1 inch by 5 inches with a thickness of .064 inches. When forming the U-channel, bends are created, and it is necessary to consider the minimum bend radius for aluminum, which is typically specified as the material thickness or slightly more depending on the process used.

The flat layout dimension involves calculating the total length of the straight sections of the channel and adding the lengths of the bends. The minimum bend radius is critical because it influences how much material is needed in the flat layout to account for the bends.

1. The length of the channel consists of three main segments:

• Two vertical sides of 1 inch (which are the legs of the “U” shape).

• One horizontal bottom segment of 5 inches.

2. When you make the bends at the ends of the vertical sides, you need to add the extension due to the bend radius. The minimum bend radius generally requires an additional amount of material for each bend. In this case, each bend will require a certain amount of additional length to accommodate the U shape without deformation.

The effective calculation