What is the consequence of exceeding the minimum radius of bend in metal?

Exceeding the minimum radius of bend in metal can lead to potential critical weakening of the part. This is due to the fact that when a bend is made too tightly, it can introduce stress concentrations and micro-cracks within the material, which compromise its structural integrity. Metals have a specified minimum bend radius to ensure that the material remains within its elastic limits during the bending process. If the bend radius is less than this minimum, the material may not only deform plastically but could also undergo fracture or fatigue over time, leading to failure.

The other options do not accurately reflect the consequences of not adhering to the minimum bend radius. While it might seem that bending could enhance durability or improve aerodynamics, these outcomes are only possible under proper bending conditions. When the bending is done correctly—above the minimum radius—the structural performance of the component is maintained, maximizing its intended function and longevity.