Hi, I know this is more of a mech engineering
question than an EE one, but here goes. :o)

I need to drill a square tube, hardened aluminium,
to make it as LIGHT as possible. The square tube
is 25mm across each edge, and used on a racing
motorcycle for a non-critical purpose, ie it's
not part of the drivechain!! It's about 1.2mm
thickness wall (25mm x 25mm x 1.2mm) if that
helps.

From my rather "fuzzy logic" examination of the
stucture the square tubing is not stressed under
flexion, but it will be exposed to compression
and expansion forces, so there is nothing to bend
it, but it needs good strength for compressing
and stretching forces... ;o)

I'm not after formulae as the problem is slightly
more complex than what I have posted, but any
general ground rules and "reasons why" will be
really appreciated.

Do we drill the tubing with large diameter
holes, or lots of small holes, and why/how
will each method give the BEST STRENGTH for
the MAX amount of weight lost???

Thanks guys! :o)
-Roman

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