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In Ver 9.1, I would use the green geometry as a 'boundry' - set for 'outside'. I think.........
Should be the same in ver X+
You may have to play with the inside/outside/offsets
HTH
I'm not sure that what you describe is possible.
Here is my take on a blend from .125 rad to .250 at the corner.
Take a look and see. I have done 3 different blends on the 3 edges.
HTH
See the Attachment below... it's in MC9
CORNER_RADIUS-BT.zip
I think you need to 'stress relieve' them twice - both before and after roughing . Check with a heat treater but I believe 550 deg to 600 deg F for 1 hr would work nicely.
It's possible the 2nd stress relieve wouldn't be necessary ..........
In my experience, any wrought copper warps horribly when machined, unless stress relieved.
HTH
Good luck
You can narrow it down a bit if you can tell if it is a die cast, investment cast or sand cast part.
Automotive parts are usually die cast or sand cast.
Investment cast would probably be A386 alum.
Looks like die cast uses A380 - A386 quick Google search
You might call a foundry and ask them what alloys they normally use.
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